Feminine pad with barrier cuffs

ABSTRACT

A disposable absorbent article having barrier cuffs is disclosed herein. The disposable absorbent article has improved pad curl characteristics which can facilitate application of the disposable absorbent article.

FIELD

The present invention pertains to feminine disposable absorbent articlescomprising barrier cuffs.

BACKGROUND

Disposable absorbent articles having barrier cuffs are currently on themarket. For example, many brands of disposable diaper employ barriercuffs to help reduce the likelihood of leakage. In general, the barriercuffs comprise a pre-strained elastic strand or plurality thereof whichcause the barrier cuff to stand up when the diaper is in use. Withoutthe feature of standing up, the barrier cuffs would be relativelyineffective at preventing or reducing the likelihood of leakage.

Typically, diapers are folded when packaged. In most instances, packageddiapers are folded along what is generally a lateral centerline whichbisects the length of the diaper. Because the elastic of the barriercuff is pre-strained, the barrier cuff urges the diaper into its foldedstate. In donning the diaper on a wearer, the pre-strained elastics helpurge the diaper onto the body and can help conform the diaper thereto.

In the feminine article context, particularly sanitary napkins orfeminine pads, barrier cuffs are not as prevalent as they are withdiapers. But similar to diapers, barrier cuffs for feminine pads alsoinclude pre-strained elastics. And, much like diapers, feminine pads arealso typically folded when packaged. For example, feminine pads may befolded along a lateral centerline much like diapers, or in someinstances, feminine pads may comprise multiple folds, e.g. folded inthirds. Similar to the barrier cuffs of diapers, the barrier cuffs ofthe feminine pads also urge the feminine pad into its folded state.However, in contrast to diapers, when donning feminine pads, thefeminine pad is typically applied and adhered to the underwear of thewearer as opposed to being directly applied to the body. Because thebarrier cuffs tend to urge the feminine pads into their folded state,application of the feminine pad to underwear may prove difficult. Evenwhere the feminine pad comprises a fastening adhesive, the barrier cuffelastics may overcome the adhesive forces. And while some conventionalarticles attempt to abate the forces of the barrier cuff, suchattempts—while mitigating the effect of the barrier cuffs regardingurging into a folded position—typically cause ends of the feminine padto curl inward. And since, the fastening adhesive for feminine pads istypically centrally located, the ends can be difficult to uncurl duringdonning. Unfortunately, the difficult application of the feminine padscould dissuade consumers from purchasing feminine pads with barriercuffs despite the added protection of the barrier cuffs.

Accordingly, there is a need for feminine pads with barrier cuffs thatcan facilitate application.

SUMMARY

Disposable absorbent article in accordance with the present inventioncan facilitate the application of the article for the wearer. Forexample, the application of the article into the panty of a wearer maybe facilitated because of the reduced pad curl as described herein.

In some forms, disposable absorbent articles of the present inventioncomprises a longitudinal axis and a lateral axis perpendicular to thelongitudinal axis. The disposable absorbent article further comprises achassis having first and second longitudinal side edges extendinggenerally parallel to the longitudinal axis, a pair of end edges joiningthe first and second longitudinal side edges on opposite ends of thechassis, the chassis further comprising a topsheet; a backsheet; and anabsorbent core disposed between the topsheet and the backsheet. Afastening adhesive is disposed on a garment-facing surface of thechassis. Additionally, a first cuff extends along the first longitudinalside edge, and a second cuff extends along the second longitudinal edge.And, the article has a flexibility factor of less than 240 and anaverage pad curl of less than 3.0 mm.

In some forms, a disposable absorbent article comprises a longitudinalaxis and a lateral axis perpendicular to the longitudinal axis. Thedisposable absorbent article further comprises a chassis having firstand second longitudinal side edges extending generally parallel to thelongitudinal axis, a pair of end edges joining the first and secondlongitudinal side edges on opposite ends of the chassis, the chassisfurther comprising a topsheet; a backsheet; and an absorbent coredisposed between the topsheet and the backsheet. A fastening adhesive isdisposed on a garment-facing surface of the chassis. Additionally, afirst cuff extends along the first longitudinal side edge, and a secondcuff extends along the second longitudinal edge. And, the article has aflexibility factor of less than 190 and an average pad curl of less than7.5 mm.

In some forms, a disposable absorbent article comprises a longitudinalaxis and a lateral axis perpendicular to the longitudinal axis. Thedisposable absorbent article further comprises a chassis having firstand second longitudinal side edges extending generally parallel to thelongitudinal axis, a pair of end edges joining the first and secondlongitudinal side edges on opposite ends of the chassis, the chassisfurther comprising a topsheet; a backsheet; and an absorbent coredisposed between the topsheet and the backsheet. A fastening adhesive isdisposed on a garment-facing surface of the chassis. Additionally, afirst cuff extends along the first longitudinal side edge, and a secondcuff extends along the second longitudinal edge. And, the article has anaverage pad curl that satisfies the following equation:

APC≦(−0.0338 FF+8.7879).

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which the designations are used todesignate substantially identical elements and in which:

FIG. 1 is a plan view showing an exemplary embodiment of a femininearticle, i.e. feminine pad.

FIG. 2A is a cross sectional view of the feminine pad of FIG. 1 takenalong line 2-2.

FIG. 2B is a cross-sectional view of an alternate form of a feminine padconstructed in accordance with the present invention.

FIG. 3A is plan view showing the feminine pad of FIG. 1 showing theadditional feature of barrier cuffs.

FIG. 3B is a close up view of the elastic member of one of the barriercuffs of the feminine pad of FIG. 3A.

FIG. 3C is a close up view of another configuration of the elasticmembers of the barrier cuffs for the feminine pads described herein.

FIG. 3D is a close up view of another configuration of the elasticmembers of the barrier cuffs for the feminine pads described herein.

FIG. 4 is a schematic side view showing a feminine pad and exemplaryfold lines.

FIG. 5 shows representative female body shapes of differing BMI wherethe transverse plane B:B is determined at the gluteal sulcus.

FIG. 6 shows representative female morphological measurements taken atplane B:B of FIG. 5, including thigh spacing, thigh diameter parallel tothe sagittal plane (thigh length), and thigh diameter parallel to thecoronal plane (thigh width).

FIG. 7A shows an approximation of the open area of the crotch on thecoronal plane, defined at the location where inner thighs 1100A and1100B intersect the torso 1120 and the gluteal sulcus for a high BMIvalue, e.g. 35.

FIG. 7B shows an approximation of the open area of the crotch on thecoronal plane defined at the location where inner thighs intersect thetorso and the gluteal sulcus for a low BMI value, e.g. 15.

FIG. 8 depicts a portion of a testing apparatus which is utilized tomeasure properties of a sample regarding a machine direction and a crossmachine direction.

FIG. 9 is a graph depicting average pad curl versus the average crossdirection peak load of a plurality of measured samples.

FIG. 10 is a graph depicting average pad curl versus the flexibilityfactor of a plurality of measured samples.

DETAILED DESCRIPTION

Feminine pads of the present invention can provide flexibility to allowfor a comfortable fit and can provide facilitated application to theunderwear of the user. For the purposes of this disclosure, reference toa feminine pad, disposable absorbent article or absorbent article willbe used. However, the present invention may be applied to a plurality offeminine articles including, but not limited to, sanitary napkins,pantiliners, adult incontinence pads, menstrual pads, etc.

There are several factors to consider when creating a feminine pad withbarrier leg cuffs, particularly if the focus is facilitation ofapplication. First, the stiffness of the pad is an important factor.Typically, thinner pads offer less stiffness than their bulkiercounterparts. While bulkier pads may resist the forces exerted by thebarrier cuffs, bulkier pads are less desirable because they can causethe feminine pad to lose its discreetness during use. And, someflexibility in the absorbent core can allow the feminine pad to adjustmore readily to the contours of the body of a user during use. Second,the stability of the feminine pad during application is an importantvariable. The feminine pad ideally, should open easily and lay flat forapplication to the underwear of the user. The forces exerted upon thearticle by the barrier cuffs should be counteracted such that thefeminine pad can be easily flattened without the ends of the femininepad curling or at least a reduced amount of curling. Third, barriercuffs associated with the feminine pad need to provide functionalgasketing. Namely, the barrier cuffs need to stand up during use andcontact the body of the wearer in an appropriate location to reduce thelikelihood of leakage beyond the barrier cuff.

Historical designs have required sacrifice with one or more of the abovefactors. In contrast, feminine pads constructed in accordance with thepresent disclosure take into consideration all three of these factors tocreate a new feminine pad. Namely, feminine pads of the presentdisclosure can provide good core flexibility, low pad curl to facilitateapplication of the feminine pad, and barrier cuffs which stand up duringuse and contact the wearer in an appropriate location to ensure reducedlikelihood of leakage from the feminine pad.

As noted previously, some flexibility of the feminine pad is desirable.For example, referring to FIG. 1, in general, a feminine pad of thepresent invention should have flexibility in both the cross machinedirection (“CD direction”) and in the machine direction (“MDdirection”). The flexibility in the CD can allow the feminine pad tomore readily adapt to contours of a user's body. However, moreflexibility in the CD can create a potential for pad curl duringapplication. Pad curl is the extent to which the pad, adjacent the endedges 26 and 28 curl when the pad is placed on a flat surface and fullyextended thereon. Pad curl specifically operates on “corners” of thefeminine pad 10. For example, corners 26A and 26B associated with endedge 26 and corners 28A and 28B associated with end edge 28 aresusceptible to curl. Similarly, some flexibility in the MD direction isdesirable; however, high flexibility in the MD direction can create apotential for the barrier cuff forces to fold end regions 40 and 48 ofthe feminine pad 10.

Still referring to FIG. 1, the feminine pad 10 is shown and may comprisea longitudinal axis 80 and a lateral axis 90. The longitudinal axis 80generally extends parallel to the longest dimension of the feminine pad10. The lateral axis 90 extends generally perpendicular to thelongitudinal axis 80 and lies in the same plane as the feminine pad 10in a flattened state on a flat surface. The lateral axis 90 bisects thelength of the feminine pad 10 where the length is parallel to thelongitudinal axis 80, and the longitudinal axis 80 bisects the width ofthe feminine pad 10 where the width is parallel to the lateral axis 90.Additionally, as shown, the MD direction may be generally parallel tothe longitudinal axis 80 of the feminine pad 10, and the CD directionmay be generally parallel to the lateral axis 90.

The feminine pad 10 may further comprise a chassis 20 comprising aplurality of side edges 22 and 24 which extend generally parallel to thelongitudinal axis 80. A pair of end edges 26 and 28 join each of theside edges 22 and 24. One end edge 26 joins the side edges 22 and 24 inthe first end region 40 of the feminine pad 10 while the other end edge28 joins the side edges 22 and 24 in the second end region 48 of thefeminine pad 10—the second end region 48 being opposite the first endregion 40. An intermediate region 44 is disposed between the first endregion 40 and the second end region 48.

As shown, the feminine pad 10 comprises a generally elongated ovalshape. However, any suitable shape may be utilized. Some examplesinclude hourglass, offset hourglass (one end is wider than an oppositeend and a narrowed mid-section between the ends), etc. The feminine pad10 may be symmetric about the longitudinal axis 80 or asymmetric aboutthe longitudinal axis 80. Similarly, the feminine pad 10 may besymmetric about the lateral axis 90 or asymmetric about the lateral axis90.

Regarding FIG. 2A, the chassis 20 may further comprises a topsheet 203,a backsheet 207, and an absorbent structure 205 positioned between thetopsheet 203 and the backsheet 207. Additional layers are contemplatedbetween the topsheet 203 and the backsheet 207. Some examples includesecondary topsheets, acquisition layers, distribution layers, etc. Thechassis 20 further comprises a wearer-facing surface 20A and agarment-facing surface 20B. The wearer-facing surface 20A may comprisethe topsheet 203, and the garment-facing surface 20B may comprise thebacksheet.

The feminine pad 10 may further comprise a first barrier cuff 230A and asecond barrier cuff 230B and fastening adhesive 211 disposed on thegarment-facing surface 20B of the chassis 20. As shown, the fasteningadhesive 211 may not extend out laterally to the same extent as theabsorbent core 205. As such, placement of the fastening adhesive 211 maynot be able to provide much help in the way of holding down corners 26A,26B, 28A, 28B (See FIG. 1) of the feminine pad 10. As such,constructions where pad curl is reduced would be beneficial.

The first barrier cuff 230A and the second barrier cuff 230B may beattached to the chassis 20 in any suitable location. For example, asshown, the first barrier cuff 230A and the second barrier cuff 230B maybe attached to a wearer-facing surface 20A of the chassis 20. As shown,the first barrier cuff 230A and the second barrier cuff 230B areattached to the topsheet 203. In some forms, the first barrier cuff 230Aand the second barrier cuff 230B may be attached to a garment-facingsurface 20B of the chassis 20. For example, the first barrier cuff 230Aand the second barrier cuff 230B may be attached to the backsheet 207.Some examples of other suitable barrier cuffs are described in U.S. Pat.No. 4,695,278; U.S. Pat. No. 4,704,115; U.S. Pat. No. 4,795,454; U.S.Pat. No. 4,909,803; U.S. Patent Application Publication No.2009/0312730.

As shown, in some forms, the first barrier cuff 230A comprises a firstcover 231 and a first elastic member 233. The second barrier cuff 230Bcomprises a second cover 235 and a second elastic member 237. As shown,the first cover 231 may fully enclose the first elastic member 233.Similarly, the second cover 235 may fully enclose the second elasticmember 237.

While the first barrier cuff 230A and the second barrier cuff 230B areshown as discrete elements which are attached to the chassis 20, anysuitable configuration may be utilized. For example, the first cover 231and/or the second cover 235 may comprise a portion of the topsheet 203and/or a portion of the backsheet 207. In such forms, the first barriercuff 230A and/or the second barrier cuff 230B may be integrally formedwith the chassis 20. A form where the first barrier cuff 230A and thesecond barrier cuff 230B are integrally formed with the chassis 20 isshown in FIG. 2B and discussed hereafter.

Referring to FIGS. 2A and 2B, the first elastic member 233 and thesecond elastic member 237 may be attached to the first cover 231 and thesecond cover 235, respectively, by any suitable means. In one example,the first elastic member may be adhesively attached to the first cover231. Similarly, the second elastic member 237 may be adhesively attachedto the second cover 235. For example, as shown, first adhesive portions251 and 253 may attach the elastic members 233 and 237 to theirrespective covers 231 and 235. Similarly, second adhesive portions 255and 257 may attach their respective covers 231 and 235 to the topsheet203. As described below, the first elastic member 233 and the secondelastic member 237 may be attached in only a portion the first cover 231and second cover 235, respectively. Additional forms are contemplatedwhere the first elastic member 233 and/or the second elastic member 237are attached to the chassis 20 in conjunction with or independently fromtheir respective covers 231 and 235.

Referring back to FIGS. 1 and 2A, the elastic members 233 and 237 may bedisposed laterally inboard of side edges 205A and 205B of the absorbentcore 205. In other forms, the elastic members 233 and 237 may bedisposed laterally outboard of the side edges 205A and 205B of theabsorbent core 205. Still in other forms, the elastic members 233 and237 may be disposed laterally inboard of the side edges 205A and 205B ofthe absorbent core 205 in the first end region 40 and the second endregion 48 but laterally outboard of side edges 205A and 205B of theabsorbent core 205 in the intermediate region 44. Additional forms arecontemplated where the elastic members 233 and 237 are disposedlaterally inboard of the side edges 205A and 205B of the absorbent core205 in the first end region 40 but are disposed outboard of the sideedges 205A and 205B of the absorbent core 205 in the intermediate region44 and/or the second end region 48.

Referring back to FIG. 2B, and as discussed previously, the firstbarrier cuff 230A and the second barrier cuff 230B may comprise aportion of the topsheet 203 and the backsheet 207. The first elasticmember 233 and the second elastic member 235 may be attached only to aportion of the topsheet 203 and backsheet 205. In other forms, the firstelastic member 233 and the second elastic member 235 may be attached tothe topsheet 203 and backsheet 205 at their respective ends as describedhereafter. As shown, the elastic members 233 and 237 may be disposedlaterally outboard of the side edges 205A and 205B of the absorbent core205.

The elastic members comprised by the barrier cuffs can be glued in, invarious glue lengths using various glues and glue amounts andplacements. Placement of the glue is yet another variable which shouldbe considered especially when designed with the core flexibility inmind. Gluing of the elastic members and the covers create anchor pointson the pad. The locations of the anchor points are important. Forexample, anchor points outboard of the side edges 205A and 205B of theabsorbent core 205 can mitigate the forces applied to the absorbent core205; however, anchor points disposed too far outboard of the side edges205A and 205B of the absorbent core 205 can increase the amount of curlon the end edges 26 and 28. Anchor points disposed too far inboard ofthe side edges 205A and 205B of the absorbent core 205 can negativelyimpact the performance of the barrier cuffs 230A and 230B. This can beparticularly important on cores with contoured shapes as wider endscoupled with a narrower crotch region can create artificial bendingpoints for which elastomeric forces can act to deform the shape of thepad.

In some forms, adhesive may be applied to the covers in a discontinuousmanner. For example, adhesive applied to the cover in the intermediateregion 44 may be disposed outboard of the side edges 205A and 205B ofthe absorbent core 205. However, in the end regions 40 and 48, adhesivemay be applied to the covers more proximal to the side edges 205A and205B of the absorbent core 205. Such application of adhesive urges thebarrier cuff inward and can help to create a more effective gasket.Adhesive patterns for barrier cuffs are discussed in depth in U.S.Patent Application Publication No. 2011/0319855.

Minimum spacing between the first barrier cuff 230A and the secondbarrier cuff 230B may be largely driven by female anatomy. However, asdiscussed previously, tradeoffs can occur where the barrier cuffs (andtheir respective elastic members) are disposed too far outboard of theabsorbent core 205 and too far inboard of the absorbent core 205. Assuch, spacing between the most distal elastic members of theirrespective barrier cuffs should be carefully selected. Starting from thenarrowest width, spacing between the most distal elastic members of thefirst barrier cuff 230A and the second barrier cuff 230B should be largeenough to allow sufficient access to the absorbent core 205 during usewhile also taking into account the forces which will be applied to thepad. If too narrow, access to a portion of the absorbent core 205 couldbe obstructed which could lead to leakage despite the barrier cuffs 230Aand 230B. In some forms of the present invention, minimum spacingbetween the elastic member of the first barrier cuff 230A and theelastic member of the second barrier cuff 230B which are most distal toone another may be at least 20 mm. Any suitable spacing may be utilized.For example, in some forms of the present invention, the spacing may begreater than or equal to about 20 mm, greater than about 30 mm, greaterthan about 33 mm, greater than about 35 mm, greater than about 40 mm,greater than about 45 mm, greater than about 50 mm, greater than about54 mm, greater than about 60 mm, greater than about 65 mm, less than orequal to about 70 mm, or less than about 65 mm, or less than about 60mm, less than about 55 mm, less than about 50 mm, less than about 45 mm,less than about 40 mm, less than about 35 mm, less than about 30 mm,less than about 25 mm, specifically including any values within theseranges or any ranges created thereby.

The above spacing can be critical in ensuring that the barrier cuffs230A and 230B contact the body of the user in an appropriate location.To gain an understanding of an appropriate location, it is pertinent tomention a few reference points of user anatomy. A “coronal plane” asused herein, describes a vertical plane which extends through a standingfemale body dividing said body into anterior and posterior portions, andsaid coronal plane extending through the shoulder and vaginal opening,bisecting vaginal opening into anterior and posterior portions. A“sagittal plane” as used herein describes a plane which extends throughthe body of a standing wearer and bisects the body of the standingwearer into left and right halves. “Thigh Spacing” means the narrowestlateral distance between the thighs—inner portions of the thigh 1100Aand 1100B (see FIG. 6)—while the person whose thighs are being measuredis in the neutral position with their feet approximately shoulder widthapart. The lateral distance being parallel to the coronal plane andbeing on a transverse plane. The transverse plane being perpendicular tothe coronal plane and extending through the Gluteal Sulcus (the glutealsulcus is often referred to as the fold of the buttock or the glutealfold of the horizontal gluteal crease). This is illustrated in FIG. 5and in FIG. 6 at plane B:B of FIG. 5.

FIG. 7A depicts an approximated area 1130A on the coronal plane whenviewing the coronal plane from the anterior portion into the posteriorportion of the body. The approximated area 1130A shown is that for ahigh BMI wearer, e.g. 35. The area 1130A is defined by an intersection1110A between a body torso 1120 and an inner thigh 1100A, anintersection 1100B between the body torso 1120 and an inner thigh 1100Band a transverse plane 1150A extending through the gluteal sulcus. Asdepicted, the area 1130A may be approximated by an inverted trapezoid.As BMI decreases, angles at the intersections 1110A and 1110B increase.In FIG. 7B, an approximated area 1130B for a lower BMI wearer, e.g. 15,is depicted. As shown, a transverse plane 1150B extending through thegluteal sulcus is much closer to the torso 1120 than of FIG. 7A. Thetransverse planes 1150A and 1150B represent relative spacing of thepanty to the torso. As depicted, the transverse plane 1150B is muchcloser to the torso 1120 than the transverse plane 1150A.

Barrier cuffs of the present invention may engage a user at theintersections 1110A and 1110B between the inner thigh 1100A and torso1120 and the inner thigh 1100B and torso 1120. Barrier cuffs which arespaced laterally inward from the intersections 1110A and 110B canincrease the likelihood of leakage. For example, when one or morebarrier cuffs engage the torso 1120 laterally inboard of theintersections 1110A and/or 1110B, the one or more barrier cuffs maydivert the path of fluids from the vaginal opening such that thesefluids travel along an outside surface of the barrier cuff rather thanto the topsheet of the pad. In contrast, barrier cuffs which engage theinner thigh 1100A and 1100B rather than the intersections 1110A and1110B, can have decreased efficacy. For example, the barrier cuffs maytend drag along the inner thigh 1100A and 1100B when donning the padsuch that in the final orientation, the barrier cuffs are slopeddownward. This downward slope of the barrier cuffs and decrease theefficacy of the barrier cuffs. The above ranges for spacing of thebarrier cuffs, were empirically determined based upon clinicalmeasurement of crotch width at the torso 1120 and extrapolation of theresults therefrom.

Yet another factor is folds of the pad. Pads generally contain one ormore folds in order to make the pad more consumer friendly and easy totransport and store. Additionally, folding the pad can reduce thelikelihood of elastic creep during storage. However, these fold linescan act as bending points upon which elastomeric forces can act todeform the shape of the pad. And, similar to the anchor points discussedabove, anchor points disposed too far beyond a fold line can beproblematic. Anchor points disposed too far beyond a fold line canincrease the torque lever arm acting on the pad in the MD directioncausing pad curl and/or the pad to fold back into the folded state.

Referring back to FIG. 1, feminine pad 10 may further comprise a firstfold line 50 and a second fold line 55. The first fold line 50 candefine a boundary between the first end region 40 and the intermediateregion 44. The second fold line 55 can define a boundary between thesecond end region 48 and the intermediate region 44. The first endregion 40 can be defined by the end edge 26, the first fold line 50, anda portion of the side edges 22 and 24 disposed between the end edge 26and the first fold line 50. The intermediate area 44 can be by the firstfold line 50, the second fold line 55, and a portion of the side edges22 and 24 disposed between the first fold line 50 and second fold line55. The second end region 48 is defined by the second fold line 55, endedge 28, and a portion of the side edges 22 and 24 disposed between theend edge 28 and the second fold line 55. The fold lines 50 and 55 can beparallel and can be co-linear (on average) with the folds which arecreated via the packaging process for the feminine pad 10.

In some forms, the first fold line 50 and second fold line 55, may beconfigured such that the fold lines 50 and 55 dissect the pad intothirds. In other forms, the first fold line 50 may be offset toward theend edge 28, and the second fold line 55 may be offset toward the endedge 28. In such forms, this can allow the second end region 48 to betucked between the intermediate region 44 and the first end region 40when the pad is in the folded configuration. Still in other forms, thefirst fold line 50 may be offset toward the end edge 26, and the secondfold line 55 may be offset toward the end edge 26. In such forms, thiscan allow the first end region 40 to be tucked between the intermediateregion 44 and the second end region 48 when the pad is in the foldedconfiguration. In some forms of the present invention, the offset eithertoward the end edge 26 or the end edge 28 may be greater than about 5mm, greater than about 10 mm, greater than about 15 mm, greater thanabout 20 mm, greater than about 25 mm, specifically including any valueswithin these ranges and any ranges formed thereby.

Referring to FIG. 3A, the first barrier cuff 230A may extend from oneend edge 26 to the other end edge 28, and the second barrier cuff 230Bmay extend from one end edge 26 to the other end edge 28. Similarly, thefirst cover 231 and the second cover 235 may extend from one end edge 26to the other end edge 28. As shown, the first elastic member 233 and thesecond elastic member 237 may be attached to their respective coversinboard of the end edges 26 and 28. For example, the first elasticmember 233 may be attached to the first cover 231 in a first attachmentzone 332 and a second attachment zone 334. In some forms, the firstattachment zone 332 extends from the first fold line 50 into the firstend region 40 by not more than 30 mm. Similarly, in some embodiments,the second attachment zone 334 extends from the second fold line 55 intothe second end region 48 by not more than 30 mm. For those forms wherethe first barrier cuff 230A and the second barrier cuff 230B comprise aportion of the topsheet 203 and the backsheet 207, the first barriercuff 230A and second barrier cuff 230B may be configured as disclosedabove.

The first attachment zone 332 and the second attachment zone 334 may bebounded by their respective fold lines, e.g. the first fold line 50 forthe first attachment zone 332 and the second fold line 55 for the secondattachment zone 334. And where adhesive is utilized to join the elasticmembers 233 and 237 to their covers, the first attachment zone 332 andthe second attachment zone 334 may be bounded by a leading edge 245A(shown in FIG. 3B) of the adhesive portion 245 which joins the elasticmember to its respective cover. Referring to FIG. 3B, ends 239 of thesecond elastic member 237 may be coterminous with a boundary of thefirst attachment zone 332. Specifically, adhesive 245 has the inboardedge 245A and an outboard edge 245B, wherein the outboard edge 245B iscoterminous with ends 239 of the second elastic member 237. However,ends 239 of the second elastic member 237 may be non-coterminous withthe outboard edge 245B of the adhesive portion 245. For example, asshown in FIG. 3C, adhesive 245 may be applied to the ends 239 of thesecond elastic member 237 and such adhesive 245 may extendlongitudinally beyond the ends 239 of the second elastic member 237. Asanother example, referring to FIG. 3D, the ends 239 of the secondelastic member 237 may extend beyond the adhesive 245 which secures thesecond elastic member 237 to its respective cover.

As stated previously, in some forms of the present invention, the firstelastic member 233 may be attached to the chassis 20 directly either inconjunction with or independently from the attachment to the first cover231. In such embodiments, the above regarding attachment zones maysimilarly apply. Namely, the first attachment zone 332 may extend fromthe first fold line 50 into the first end region 40 by not more than 20mm. Similarly, the second attachment zone 334 may extend from the secondfold line 55 into the second end region 48 by not more than 20 mm. It isbelieved that the limit of extension of the first attachment area 332and the second attachment area 334 beyond the first fold line 50 and thesecond fold line 55, respectively, reduces the potential moment armwhich urges the first end region 40 and/or the second end region 48 intothe folded position. The second elastic member 237 may be similarlyconfigured to the first elastic member 233 with regard to the firstattachment zone 332 and the second attachment zone 334. And for thoseforms where the first barrier cuff and second barrier cuff comprise aportion of the topsheet and the backsheet, the first elastic member andsecond elastic member may be similarly configured to those formsdisclosed above.

Referring to FIG. 3A, in some forms of the present invention, the firstelastic member 233 and the second elastic member 237 are attached totheir respective covers 231 and 235 continuously in the intermediateregion 44. In other forms of the present invention, the first elasticmember 233 and the second elastic member 237 may be unattached to theirrespective covers 231 and 235 in the intermediate region 44. In someforms of the present invention, the first elastic member 233 and/or thesecond elastic member 237 may be attached to their respective covers231/235 and/or the chassis 20 intermittently. For example, the firstelastic member 233 may be attached to the first cover 231 in theintermediate region 44 less than about 90 percent of a distance betweenthe first fold line 50 and the second fold line 55. In some forms of thepresent invention, the first elastic member 233 may be attached to thefirst cover 231 in the intermediate region 44 less than about 80percent, less than about 70 percent, less than about 60 percent, lessthan about 50 percent, less than about 40 percent, less than about 30percent, less than about 20 percent of the distance between the firstfold line 50 and the second fold line 55, specifically including allnumbers within these values and any and all ranges included by or withinthese values. The second elastic member 237 may be similarly configured.And for those forms where the first barrier cuff and second barrier cuffcomprise a portion of the topsheet and the backsheet, the first elasticmember and second elastic member may be similarly configured to thoseforms described above.

The problems associated with barrier cuff elastics as describedheretofore are similarly applicable for those feminine pads whichcomprise a single fold or comprise no folds. For example, for thosefeminine pads comprising only one fold, the fold line may be consideredto bisect the pad into halves. However, for the purposes of determiningthe appropriate attachment zone of the elastic members to the chassis orto their respective covers, fold lines may be approximated which dissectthe length of the pad into thirds. Similarly, for those feminine padswhich are packaged in a flat position, imaginary fold lines dissect thefeminine pad into thirds. For those feminine pads comprising more thantwo folds—where the folds are generally parallel to the lateral axis ofthe pad—the fold lines are co-linear (on average) with the folds whichare created via packaging. In such forms, the fold lines which are mostproximate to the end regions of the pad are to be considered. For thosepads of the present invention which do comprise folds, the boundarylines associated therewith may be offset as described above.

As noted previously, a stiffer article may resist the barrier cuffforces to a larger extent than a less stiff article. However, stifferarticles typically are not seen as wearer friendly as they can provide aharsh feel to the wearer and generally do not conform well to the bodyof the user. Examples of conventional articles and articles constructedin accordance with the present invention are provided hereafter.

Similarly, elastic members having a lower spring value can be utilized.However, reduction of the spring value of the elastic members cannegatively impact the functionality of the barrier cuffs. For example,elastic members having too low of a spring value can decrease thebarrier cuff height in use. The decreased height can increase thelikelihood of leakage beyond the barrier cuff.

Referring back to FIGS. 2A and 2B, the feminine pad 10 of the presentinvention may utilize any suitable topsheet 203, any suitable backsheet207, and any suitable absorbent core 205. As shown, the topsheet 203 andthe backsheet 207 may have length and width dimensions generally largerthan those of the absorbent core 205. In some forms of the presentinvention, the topsheet 203 and the backsheet 207 extend beyond theedges of the absorbent core 205 to thereby form the periphery of thefeminine pad 10. The topsheet 203, the backsheet 207, and the absorbentcore 205 may be assembled in a variety of well-known configurationsknown to those of skill in the art.

The absorbent core 205 of the present invention may comprise anysuitable shape. For example, in some forms of the present invention, theabsorbent core 205 may comprise a contoured shape, e.g. narrower in theintermediate region than in the end regions. As another example, theabsorbent core 205 may comprise a rectangular shape. As yet anotherexample, the absorbent core may comprise a tapered shape having a widerportion in one end region of the pad which tapers to a narrower endregion in the other end region of the pad. The absorbent core 205 maycomprise varying stiffness in the MD and CD.

The absorbent core 205 may comprise any absorbent member which isgenerally compressible, conformable, non-irritating to the wearer'sskin, and capable of absorbing and retaining liquids such as urine andother certain body exudates including menses. The absorbent core 205 maybe manufactured in a wide variety of sizes and shapes (e.g.,rectangular, hourglass, asymmetric, etc.) and from a wide variety ofliquid-absorbent materials commonly used in disposable feminine articlesand other absorbent articles such as comminuted wood pulp which isgenerally referred to as airfelt. The absorbent core 205 may comprisesuperabsorbent polymers (SAP) and less than 15%, less than 10%, lessthan 5%, less than 3%, or less than 1% of airfelt, or be completely freeof airfelt. Examples of other suitable absorbent materials comprisecreped cellulose wadding, meltblown polymers including coform,chemically stiffened, modified or cross-linked cellulosic fibers, tissueincluding tissue wraps and tissue laminates, absorbent foams, absorbentsponges, superabsorbent polymers (“SAP”), e.g. absorbent gellingmaterials (“AGM”), or any equivalent material or combinations ofmaterials.

The configuration and construction of the absorbent core 205 may vary(e.g., the absorbent structure 205 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones; or maycomprise one or more layers or structures). Further, the size andabsorbent capacity of the absorbent core 205 may also be varied toaccommodate a variety of wearers. However, the total absorbent capacityof the absorbent core 205 should be compatible with the design loadingand the intended use of the feminine pad 10.

In certain forms of the present invention, the absorbent core 205 can berelatively thin, such as, for example, less than about 10 mm, or lessthan about 5 mm in thickness, or less than about 3 mm, or less thanabout 1 mm in thickness. Thickness can be measured by any means known inthe art for doing so while the core is under a uniform pressure of 0.25psi. In some exemplary forms of the present invention, the absorbentcore 205 can comprise absorbent gelling materials (AGM), including AGMfibers, as is known in the art.

In some forms of the present invention, the absorbent core 205 maycomprise a plurality of multi-functional layers. For example, theabsorbent core 205 may comprise a core wrap (i.e., the layers enclosingthe absorbent material of the absorbent structure 205). The core wrapmay be formed by two nonwoven materials, substrates, laminates, films,or other materials. In a form, the core wrap may only comprise a singlematerial, substrate, laminate, or other material wrapped at leastpartially around itself. Additional layers contemplated areacquisition/distribution layers which are well known in the art.

The absorbent core 205 of the present disclosure may comprise one ormore adhesives, for example, to help immobilize the SAP or otherabsorbent materials within the core wrap and/or to ensure integrity ofthe core wrap, in particular when the core wrap is made of two or moresubstrates. The core wrap may extend to a larger area than required forcontaining the absorbent material(s) within.

Absorbent structures comprising relatively high amounts of SAP withvarious core designs are disclosed in U.S. Pat. No. 5,599,335 to Goldmanet al., EP 1,447,066 to Busam et al., WO 95/11652 to Tanzer et al., U.S.Pat. Publ. No. 2008/0312622A1 to Hundorf et al., and WO 2012/052172 toVan Malderen.

The absorbent material may comprise one or more continuous layerspresent within the core wrap with channels having no, or little (e.g.,0.1%-10%) absorbent material positioned therein. In other forms, theabsorbent material may be formed as individual pockets or stripes withinthe core wrap. In the first case, the absorbent material may be, forexample, obtained by the application of the continuous layer(s) ofabsorbent material, with the exception of the absorbent material free,or substantially free, channels. The continuous layer(s) of absorbentmaterial, in particular of SAP, may also be obtained by combining twoabsorbent layers having discontinuous absorbent material applicationpatterns, wherein the resulting layer is substantially continuouslydistributed across the absorbent particulate polymer material area, asdisclosed in U.S. Pat. Appl. Pub. No. 2008/0312622A1 to Hundorf et al.,for example.

The absorbent structure 205 may comprise a first absorbent layer and atleast a second absorbent layer. The first absorbent layer may comprise afirst material and a first layer of absorbent material, which may be100% or less of SAP, such as 85% to 100% SAP, 90% to 100% SAP, or even95% to 100% SAP, specifically including all 0.5% increments within thespecified ranges and all ranges formed therein or thereby. The secondabsorbent layer may comprise a second material and a second layer ofabsorbent material, which may also be 100% or less of SAP (including theranges specified above). Alternatively, the second absorbent layer maycomprise a combination of cellulose, commuted wood pulp, or the like incombination with SAP. The absorbent core 205 may also comprise a fibrousthermoplastic adhesive material at least partially bonding each layer ofthe absorbent material to its respective material.

The absorbent core 205 may comprise one or more pockets. The one or morepockets may be provided in addition to the one or more channels orinstead of the one or more channels. The pockets may be areas in theabsorbent structure that are free of, or substantially free of absorbentmaterial, such as SAP (including the ranges specified above). Otherforms and more details regarding channels and pockets that are free of,or substantially free of absorbent materials, such as SAP, withinabsorbent cores are discussed in greater detail in U.S. PatentApplication Publication Nos. 2014/0163500, 2014/0163506, and2014/0163511, all published on Jun. 12, 2014.

Example absorbent structures for use as the absorbent core 205 of thepresent disclosure that have achieved wide acceptance described in U.S.Pat. No. 4,610,678, entitled “High-Density Absorbent Structures” issuedto Weisman et al., on Sep. 9, 1986; U.S. Pat. No. 4,673,402, entitled“Absorbent Articles With Dual-Layered Cores”, issued to Weisman et al.,on Jun. 16, 1987; U.S. Pat. No. 4,888,231, entitled “Absorbent CoreHaving A Dusting Layer”, issued to Angstadt on Dec. 19, 1989; and U.S.Pat. No. 4,834,735, entitled “High Density Absorbent Members HavingLower Density and Lower Basis Weight Acquisition Zones”, issued toAlemany et al., on May 30, 1989. The absorbent core may further comprisethe dual core system containing an acquisition/distribution core ofchemically stiffened fibers positioned over an absorbent storage core asdetailed in U.S. Pat. No. 5,234,423, entitled “Absorbent Article WithElastic Waist Feature and Enhanced Absorbency” issued to Alemany et al.,on Aug. 10, 1993; and in U.S. Pat. No. 5,147,345 entitled “HighEfficiency Absorbent Articles For Incontinence Management”, issued toYoung et al. on Sep. 15, 1992.

The absorbent structure may be a heterogeneous mass comprisingenrobeable elements and one or more portions of foam pieces. Thediscrete portions of foam pieces are open-celled foam. The enrobeableelements may be a web such as, for example, nonwoven, a fibrousstructure, an air-laid web, a wet laid web, a high loft nonwoven, aneedlepunched web, a hydroentangled web, a fiber tow, a woven web, aknitted web, a flocked web, a spunbond web, a layered spunbond/meltblown web, a carded fiber web, a coform web of cellulose fiber and meltblown fibers, a coform web of staple fibers and melt blown fibers, andlayered webs that are layered combinations thereof. The foam may be aHigh Internal Phase Emulsion (HIPE) foam. Exemplary enrobeable elementsand foams are described in greater detail below.

The open-cell foam pieces may comprise between 1% of the heterogeneousmass by volume to 99% of the heterogeneous mass by volume, such as, forexample, 5% by volume, 10% by volume, 15% by volume, 20% by volume, 25%by volume, 30% by volume, 35% by volume, 40% by volume, 45% by volume,50% by volume, 55% by volume, 60% by volume, 65% by volume, 70% byvolume, 75% by volume, 80% by volume, 85% by volume, 90% by volume, or95% by volume.

The heterogeneous mass may have void space found between the enrobeableelements, between the enrobeable elements and the enrobed elements, andbetween enrobed elements. The void space may contain a gas such as air.The void space may represent between 1% and 95% of the total volume fora fixed amount of volume of the heterogeneous mass, such as, forexample, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%,70%, 75%, 80%, 85%, 90% of the total volume for a fixed amount of volumeof the heterogeneous mass.

The combination of open-cell foam pieces and void space within theheterogeneous mass may exhibit an absorbency of between 10 g/g to 200g/g of the, such as for example, between 20 g/g and 190 g/g of theheterogeneous mass, such as, for example 30 g/g, 40 g/g, 60 g/g, 80 g/g,100 g/g, 120 g/g, 140 g/g 160 g/g 180 g/g or 190 g/g of theheterogeneous mass. Absorbency may be quantified according to the EDANANonwoven Absorption method 10.4-02.

The open-cell foam pieces are discrete foam pieces intertwined withinand throughout a heterogeneous mass such that the open-cell foam enrobesone or more of the enrobeable elements such as, for example, fiberswithin the mass. The open-cell foam may be polymerized around theenrobeable elements.

A discrete open-cell foam piece may enrobe more than one enrobeableelement. The enrobeable elements may be enrobed together as a bunch.Alternatively, more than one enrobeable element may be enrobed by thediscrete open-cell foam piece without contacting another enrobeableelement.

A discrete open-cell foam piece may be immobilized such that thediscrete open-cell foam piece does not change location within theheterogeneous mass during use of the absorbent structure.

A plurality of discrete open-cell foams may be immobilized such that thediscrete open-cell foam pieces do not change location within theheterogeneous mass during use of the absorbent structure.

One or more discrete foam pieces may be immobilized within theheterogeneous mass such that the one or more discrete foam pieces do notchange location after being spun at 300 rotations per minute for 30seconds.

The open-cell foam pieces may be discrete. Open-cell foam pieces areconsidered discrete in that they are not continuous throughout theentire heterogeneous mass. Not continuous throughout the entireheterogeneous mass represents that at any given point in theheterogeneous mass, the open-cell absorbent foam is not continuous in atleast one of the cross sections of a longitudinal, a vertical, and alateral plane of the heterogeneous mass. The absorbent foam may or maynot be continuous in the lateral and the vertical planes of the crosssection for a given point in the heterogeneous mass. The absorbent foammay or may not be continuous in the longitudinal and the vertical planesof the cross section for a given point in the heterogeneous mass. Theabsorbent foam may or may not be continuous in the longitudinal and thelateral planes of the cross section for a given point in theheterogeneous mass.

When the open-cell foam is not continuous in at least one of the crosssections of the longitudinal, the vertical, and the lateral plane of theheterogeneous mass, one or both of either the enrobeable elements or theopen-cell foam pieces may be bi-continuous throughout the heterogeneousmass.

The open-cell foam pieces may be located at any point in theheterogeneous mass. A foam piece may be surrounded by the elements thatmake up the enrobeable elements. A foam piece may be located on theouter perimeter of the heterogeneous mass such that only a portion ofthe foam piece is entangled with the elements of the heterogeneous mass.

The open-cell foam pieces may expand upon being contacted by a fluid toform a channel of discrete open-cell foam pieces. The open-cell foampieces may or may not be in contact prior to being expanded by a fluid.

An open-celled foam may be integrated onto the enrobeable elements priorto being polymerized. The open-cell foam pieces may be partiallypolymerized prior to being impregnated into or onto the enrobeableelements such that they become intertwined. After being impregnated intoor onto the enrobeable elements, the open-celled foam in either a liquidor solid state are polymerized to form one or more open-cell foampieces. The open-celled foam may be polymerized using any known methodincluding, for example, heat, UV, and infrared. Following thepolymerization of a water in oil open-cell foam emulsion, the resultingopen-cell foam is saturated with aqueous phase that needs to be removedto obtain a substantially dry open-cell foam. Removal of the saturatedaqueous phase or dewatering may occur using nip rollers, and vacuum.Utilizing a nip roller may also reduce the thickness of theheterogeneous mass such that the heterogeneous mass will remain thinuntil the open-cell foam pieces entwined in the heterogeneous mass areexposed to fluid.

The open cell foam pieces may be impregnated prior to polymerizationinto or onto two or more different enrobeable elements that are combinedto create a heterogeneous mixture of enrobeable elements. The two ormore different enrobeable elements may be intertwined such that oneenrobeable element may be surrounded by multiples of the secondenrobeable element, such as, for example by using more than one type offiber in a mixture of fibers or by coating one or more fibers withsurfactant. The two or more different enrobeable elements may be layeredwithin the heterogeneous mass along any of the vertical, longitudinal,and/or lateral planes such that the enrobeable elements are profiledwithin the heterogeneous mass for an enrobeable element inherentproperty or physical property, such as, for example, hydrophobicity,fiber diameter, fiber or composition. It is understood that any inherentproperty or physical property of the enrobeable elements listed iscontemplated herein.

Dependent upon the desired foam density, polymer composition, specificsurface area, or pore-size (also referred to as cell size), theopen-celled foam may be made with different chemical composition,physical properties, or both. For instance, dependent upon the chemicalcomposition, an open-celled foam may have a density of 0.0010 g/cc toabout 0.25 g/cc, or from 0.002 g/cc to about 0.2 g/cc, or from about0.005 g/cc to about 0.15 g/cc, or from about 0.01 g/cc to about 0.1g/cc, or from about 0.02 g/cc to about 0.08 g/cc, or about 0.04 g/cc.

Open-cell foam pore-sizes may range in average diameter of from 1 to 800μm, such as, for example, between 50 and 700 μm, between 100 and 600 μm,between 200 and 500 μm, between 300 and 400 μm.

The foam pieces may have a relatively uniform cell size. For example,the average cell size on one major surface may be about the same or varyby no greater than 10% as compared to the opposing major surface. Theaverage cell size of one major surface of the foam may differ from theopposing surface. For example, in the foaming of a thermosettingmaterial it is not uncommon for a portion of the cells at the bottom ofthe cell structure to collapse resulting in a lower average cell size onone surface. The cell size may be determined based upon the method foundbelow.

The foams preferably are relatively open-celled. This refers to theindividual cells or pores of the foam being in substantiallyunobstructed communication with adjoining cells. The cells in suchsubstantially open-celled foam structures have intercellular openings orwindows that are large enough to permit ready fluid transfer from onecell to another within the foam structure. For purpose of the presentinvention, a foam is considered “open-celled” if at least about 80% ofthe cells in the foam that are at least 1 μm in average diameter sizeare in fluid communication with at least one adjoining cell.

In addition to being open-celled, the foams may be sufficientlyhydrophilic to permit the foam to absorb aqueous fluids, for example theinternal surfaces of a foam may be rendered hydrophilic by residualhydrophilizing surfactants or salts left in the foam followingpolymerization, by selected post-polymerization foam treatmentprocedures (as described hereafter), or combinations of both.

For example when used in certain absorbent articles, an open-cell foammay be flexible and exhibit an appropriate glass transition temperature(Tg). The Tg represents the midpoint of the transition between theglassy and rubbery states of the polymer.

The Tg of a region may be less than about 200° C. for foams used atabout ambient temperature conditions, or less than about 90° C. The Tgmay be less than 50° C.

The open-cell foam pieces may be distributed in any suitable mannerthroughout the heterogeneous mass. The open-cell foam pieces may beprofiled along the vertical axis such that smaller pieces are locatedabove larger pieces. Alternatively, the pieces may be profiled such thatsmaller pieces are below larger pieces. The open-cell pieces may beprofiled along a vertical axis such that they alternate in size alongthe axis.

The open-cell foam pieces may be profiled along the longitudinal axissuch that smaller pieces are located in front of larger pieces.Alternatively, the pieces may be profiled such that smaller pieces arebehind larger pieces. The open-cell pieces may be profiled along alongitudinal axis such that they alternate in size along the axis.

The open-cell foam pieces may be profiled along the lateral axis suchthe size of the pieces goes from small to large or from large to smallalong the lateral axis. Alternatively, the open-cell pieces may beprofiled along a lateral axis such that they alternate in size along theaxis.

The open-cell foam pieces may be profiled along any one of thelongitudinal, lateral, or vertical axis based on one or morecharacteristics of the open-cell foam pieces. Characteristics by whichthe open-cell foam pieces may be profiled within the heterogeneous massmay include, for example, absorbency, density, cell size, andcombinations thereof.

The open-cell foam pieces may be profiled along any one of thelongitudinal, lateral, or vertical axis based on the composition of theopen-cell foam. The open-cell foam pieces may have one compositionexhibiting desirable characteristics in the front of the heterogeneousmass and a different composition in the back of the heterogeneous massdesigned to exhibit different characteristics. The profiling of theopen-cell foam pieces may be either symmetric or asymmetric about any ofthe prior mentioned axes or orientations.

The open-cell foam pieces may be distributed along the longitudinal andlateral axis of the heterogeneous mass in any suitable form. Theopen-cell foam pieces may be distributed in a manner that forms a designor shape when viewed from a top planar view. The open-cell foam piecesmay be distributed in a manner that forms stripes, ellipticals, squares,or any other known shape or pattern.

In an embodiment, the open-cell foam pieces are in the form of stripes.The stripes may be formed during the formation of the heterogeneous massor by formation means after polymerization. The stripes may run alongthe longitudinal length of the heterogeneous mass layer, along thelateral length of the heterogeneous mass layer, or a combination of boththe longitudinal length and the lateral length. The stripes may becontinuous or discontinuous. The stripes may run along a diagonal toeither the longitudinal length or the lateral length of theheterogeneous mass layer. The stripes may be separated by canals.

In an embodiment, the open-cell foam forms a grid comprisingdiscontinuous canals. The canals may run along the longitudinal lengthof the heterogeneous mass layer, along the lateral length of theheterogeneous mass layer, or a combination of both the longitudinallength and the lateral length.

Formation means known for deforming a generally planar fibrous web intoa three-dimensional structure are utilized in the present invention tomodify as-made absorbent materials into absorbent materials havingrelatively higher permeability without a significant correspondingdecrease in capillary pressure. Formation means may comprise a pair ofinter-meshing rolls, typically steel rolls having inter-engaging ridgesor teeth and grooves. However, it is contemplated that other means forachieving formation can be utilized, such as the deforming roller andcord arrangement disclosed in US 2005/0140057 published Jun. 30, 2005.Therefore, all disclosure of a pair of rolls herein is consideredequivalent to a roll and cord, and a claimed arrangement reciting twointer-meshing rolls is considered equivalent to an inter-meshing rolland cord where a cord functions as the ridges of a mating inter-engagingroll. In one embodiment, the pair of intermeshing rolls of the instantinvention can be considered as equivalent to a roll and an inter-meshingelement, wherein the inter-meshing element can be another roll, a cord,a plurality of cords, a belt, a pliable web, or straps. Likewise, otherknown formation technologies, such as creping, necking/consolidation,corrugating, embossing, button break, hot pin punching, and the like arebelieved to be able to produce absorbent materials having some degree ofrelatively higher permeability without a significant correspondingdecrease in capillary pressure. Formation means utilizing rolls include“ring rolling”, a “SELF” or “SELF′ing” process, in which SELF stands forStructural Elastic Like Film, as “micro-SELF”, and “rotary knifeaperturing” (RKA); as described in U.S. Pat. No. 7,935,207 Zhao et al.,granted May 3, 2011.

The distribution may be optimized dependent on the intended use of theheterogeneous mass. For example, a different distribution may be chosenfor the absorption of aqueous fluids such as urine when used in a diaperor water when used in a paper towel versus for the absorption of aproteinaceous fluid such as menses. Further, the distribution may beoptimized for uses such as dosing an active or to use the foam as areinforcing element.

Different types of foams may be used in one heterogeneous mass. Forexample, some of the foam pieces may be polymerized HIPE while otherpieces may be made from polyurethane. The pieces may be located atspecific locations within the mass based on their properties to optimizethe performance of the heterogeneous mass.

The foam pieces may be similar in composition yet exhibit differentproperties. For example, using HIPE foam, some foam pieces may be thinuntil wet while others may have been expanded within the heterogeneousmass.

The foam pieces and enrobeable elements may be selected to complementeach other. For example, a foam that exhibits high permeability with lowcapillarity may enrobe an element that exhibits high capillarity to wickthe fluid through the heterogeneous mass. It is understood that othercombinations may be possible wherein the foam pieces complement eachother or wherein the foam pieces and enrobeable elements both exhibitsimilar properties.

Profiling may occur using more than one heterogeneous mass with eachheterogeneous mass having one or more types of foam pieces. Theplurality of heterogeneous masses may be layered so that the foam isprofiled along any one of the longitudinal, lateral, or vertical axisbased on one or more characteristics of the open-cell foam pieces for anoverall product that contains the plurality of heterogeneous masses.Further, each heterogeneous mass may have a different enrobeable elementto which the foam is attached. For example, a first heterogeneous massmay have foam particles enrobing a nonwoven while a second heterogeneousmass adjacent the first heterogeneous mass may have foam particlesenrobing a film or one surface of a film.

The open-celled foam may be a thermoset polymeric foam made from thepolymerization of a High Internal Phase Emulsion (HIPE), also referredto as a polyHIPE. To form a HIPE, an aqueous phase and an oil phase arecombined in a ratio between about 8:1 and 140:1. The aqueous phase tooil phase ratio may be between about 10:1 and about 75:1, and theaqueous phase to oil phase ratio may be between about 13:1 and about65:1. This is termed the “water-to-oil” or W:O ratio and may be used todetermine the density of the resulting polyHIPE foam. As discussed, theoil phase may contain one or more of monomers, comonomers,photoinitiators, crosslinkers, and emulsifiers, as well as optionalcomponents. The water phase may contain water and one or more componentssuch as electrolyte, initiator, or optional components.

The open-cell foam may be formed from the combined aqueous and oilphases by subjecting these combined phases to shear agitation in amixing chamber or mixing zone. The combined aqueous and oil phases aresubjected to shear agitation to produce a stable HIPE having aqueousdroplets of the desired size. An initiator may be present in the aqueousphase, or an initiator may be introduced during the foam making process,or after the HIPE has been formed. The emulsion making process producesa HIPE where the aqueous phase droplets are dispersed to such an extentthat the resulting HIPE foam will have the desired structuralcharacteristics. Emulsification of the aqueous and oil phase combinationin the mixing zone may involve the use of a mixing or agitation devicesuch as an impeller, by passing the combined aqueous and oil phasesthrough a series of static mixers at a rate necessary to impart therequisite shear, or combinations of both. Once formed, the HIPE may thenbe withdrawn or pumped from the mixing zone. One method for formingHIPEs using a continuous process is described in U.S. Pat. No. 5,149,720(DesMarais et al), issued Sep. 22, 1992; U.S. Pat. No. 5,827,909(DesMarais) issued Oct. 27, 1998; and U.S. Pat. No. 6,369,121 (Catalfamoet al.) issued Apr. 9, 2002.

The emulsion may be withdrawn or pumped from the mixing zone andimpregnated into or onto a mass prior to being fully polymerized. Oncefully polymerized, the foam pieces and the elements are intertwined suchthat discrete foam pieces are bisected by the elements comprising themass and such that parts of discrete foam pieces enrobe portions of oneor more of the elements comprising the heterogeneous mass.

Following polymerization, the resulting foam pieces are saturated withaqueous phase that needs to be removed to obtain substantially dry foampieces. Foam pieces may be squeezed free of most of the aqueous phase byusing compression, for example by running the heterogeneous masscomprising the foam pieces through one or more pairs of nip rollers. Thenip rollers may be positioned such that they squeeze the aqueous phaseout of the foam pieces. The nip rollers may be porous and have a vacuumapplied from the inside such that they assist in drawing aqueous phaseout of the foam pieces. Nip rollers may be positioned in pairs, suchthat a first nip roller is located above a liquid permeable belt, suchas a belt having pores or composed of a mesh-like material and a secondopposing nip roller facing the first nip roller and located below theliquid permeable belt. One of the pair, for example the first nip rollermay be pressurized while the other, for example the second nip roller,may be evacuated, so as to both blow and draw the aqueous phase out theof the foam. The nip rollers may also be heated to assist in removingthe aqueous phase. Nip rollers may be applied to non-rigid foams, thatis, foams whose walls would not be destroyed by compressing the foampieces.

In place of or in combination with nip rollers, the aqueous phase may beremoved by sending the foam pieces through a drying zone where it isheated, exposed to a vacuum, or a combination of heat and vacuumexposure. Heat may be applied, for example, by running the foam though aforced air oven, IR oven, microwave oven or radiowave oven. The extentto which a foam is dried depends on the application. Greater than 50% ofthe aqueous phase may be removed. Greater than 90%, and in still otherembodiments greater than 95% of the aqueous phase may be removed duringthe drying process.

Open-cell foam may be produced from the polymerization of the monomershaving a continuous oil phase of a High Internal Phase Emulsion (HIPE).The HIPE may have two phases. One phase is a continuous oil phase havingmonomers that are polymerized to form a HIPE foam and an emulsifier tohelp stabilize the HIPE. The oil phase may also include one or morephotoinitiators. The monomer component may be present in an amount offrom about 80% to about 99%, and in certain embodiments from about 85%to about 95% by weight of the oil phase. The emulsifier component, whichis soluble in the oil phase and suitable for forming a stablewater-in-oil emulsion may be present in the oil phase in an amount offrom about 1% to about 20% by weight of the oil phase. The emulsion maybe formed at an emulsification temperature of from about 10° C. to about130° C. and in certain embodiments from about 50° C. to about 100° C.

In general, the monomers will include from about 20% to about 97% byweight of the oil phase at least one substantially water-insolublemonofunctional alkyl acrylate or alkyl methacrylate. For example,monomers of this type may include C₄-C₁₈ alkyl acrylates and C₂-C₁₈methacrylates, such as ethylhexyl acrylate, butyl acrylate, hexylacrylate, octyl acrylate, nonyl acrylate, decyl acrylate, isodecylacrylate, tetradecyl acrylate, benzyl acrylate, nonyl phenyl acrylate,hexyl methacrylate, 2-ethylhexyl methacrylate, octyl methacrylate, nonylmethacrylate, decyl methacrylate, isodecyl methacrylate, dodecylmethacrylate, tetradecyl methacrylate, and octadecyl methacrylate.

The oil phase may also have from about 2% to about 40%, and in certainembodiments from about 10% to about 30%, by weight of the oil phase, asubstantially water-insoluble, polyfunctional crosslinking alkylacrylate or methacrylate. This crosslinking comonomer, or crosslinker,is added to confer strength and resilience to the resulting HIPE foam.Examples of crosslinking monomers of this type may have monomerscontaining two or more activated acrylate, methacrylate groups, orcombinations thereof. Nonlimiting examples of this group include1,6-hexanedioldiacrylate, 1,4-butanedioldimethacrylate,trimethylolpropane triacrylate, trimethylolpropane trimethacrylate,1,12-dodecyldimethacrylate, 1,14-tetradecanedioldimethacrylate, ethyleneglycol dimethacrylate, neopentyl glycol diacrylate(2,2-dimethylpropanediol diacrylate), hexanediol acrylate methacrylate,glucose pentaacrylate, sorbitan pentaacrylate, and the like. Otherexamples of crosslinkers contain a mixture of acrylate and methacrylatemoieties, such as ethylene glycol acrylate-methacrylate and neopentylglycol acrylate-methacrylate. The ratio of methacrylate:acrylate groupin the mixed crosslinker may be varied from 50:50 to any other ratio asneeded.

Any third substantially water-insoluble comonomer may be added to theoil phase in weight percentages of from about 0% to about 15% by weightof the oil phase, in certain embodiments from about 2% to about 8%, tomodify properties of the HIPE foams. “Toughening” monomers may bedesired which impart toughness to the resulting HIPE foam. These includemonomers such as styrene, vinyl chloride, vinylidene chloride, isoprene,and chloroprene. Without being bound by theory, it is believed that suchmonomers aid in stabilizing the HIPE during polymerization (also knownas “curing”) to provide a more homogeneous and better formed HIPE foamwhich results in better toughness, tensile strength, abrasionresistance, and the like. Monomers may also be added to confer flameretardancy as disclosed in U.S. Pat. No. 6,160,028 (Dyer) issued Dec.12, 2000. Monomers may be added to confer color, for example vinylferrocene, fluorescent properties, radiation resistance, opacity toradiation, for example lead tetraacrylate, to disperse charge, toreflect incident infrared light, to absorb radio waves, to form awettable surface on the HIPE foam struts, or for any other desiredproperty in a HIPE foam. In some cases, these additional monomers mayslow the overall process of conversion of HIPE to HIPE foam, thetradeoff being necessary if the desired property is to be conferred.Thus, such monomers may be used to slow down the polymerization rate ofa HIPE. Examples of monomers of this type may have styrene and vinylchloride.

The oil phase may further contain an emulsifier used for stabilizing theHIPE. Emulsifiers used in a HIPE may include: (a) sorbitan monoesters ofbranched C₁₆-C₂₄ fatty acids; linear unsaturated C₁₆-C₂₂ fatty acids;and linear saturated C₁₂-C₁₄ fatty acids, such as sorbitan monooleate,sorbitan monomyristate, and sorbitan monoesters, sorbitan monolauratediglycerol monooleate (DGMO), polyglycerol monoisostearate (PGMIS), andpolyglycerol monomyristate (PGMM); (b) polyglycerol monoestersof—branched C₁₆-C₂₄ fatty acids, linear unsaturated C₁₆-C₂₂ fatty acids,or linear saturated C₁₂-C₁₄ fatty acids, such as diglycerol monooleate(for example diglycerol monoesters of C18:1 fatty acids), diglycerolmonomyristate, diglycerol monoisostearate, and diglycerol monoesters;(c) diglycerol monoaliphatic ethers of—branched C₁₆-C₂₄ alcohols, linearunsaturated C₁₆-C₂₂ alcohols, and linear saturated C₁₂-C₁₄ alcohols, andmixtures of these emulsifiers. See U.S. Pat. No. 5,287,207 (Dyer etal.), issued Feb. 7, 1995 and U.S. Pat. No. 5,500,451 (Goldman et al.)issued Mar. 19, 1996. Another emulsifier that may be used ispolyglycerol succinate (PGS), which is formed from an alkyl succinate,glycerol, and triglycerol.

Such emulsifiers, and combinations thereof, may be added to the oilphase so that they may have between about 1% and about 20%, in certainembodiments from about 2% to about 15%, and in certain other embodimentsfrom about 3% to about 12% by weight of the oil phase. Coemulsifiers mayalso be used to provide additional control of cell size, cell sizedistribution, and emulsion stability, particularly at highertemperatures, for example greater than about 65° C. Examples ofcoemulsifiers include phosphatidyl cholines and phosphatidylcholine-containing compositions, aliphatic betaines, long chain C₁₂-C₂₂dialiphatic quaternary ammonium salts, short chain C₁-C₄ dialiphaticquaternary ammonium salts, long chain C₁₂-C₂₂dialkoyl(alkenoyl)-2-hydroxyethyl, short chain C₁-C₄ dialiphaticquaternary ammonium salts, long chain C₁₂-C₂₂ dialiphatic imidazoliniumquaternary ammonium salts, short chain C₁-C₄ dialiphatic imidazoliniumquaternary ammonium salts, long chain C₁₂-C₂₂ monoaliphatic benzylquaternary ammonium salts, long chain C₁₂-C₂₂dialkoyl(alkenoyl)-2-aminoethyl, short chain C₁-C₄ monoaliphatic benzylquaternary ammonium salts, short chain C₁-C₄ monohydroxyaliphaticquaternary ammonium salts. Ditallow dimethyl ammonium methyl sulfate(DTDMAMS) may be used as a coemulsifier.

The oil phase may comprise a photoinitiator at between about 0.05% andabout 10%, and in certain embodiments between about 0.2% and about 10%by weight of the oil phase. Lower amounts of photoinitiator allow lightto better penetrate the HIPE foam, which may provide for polymerizationdeeper into the HIPE foam. However, if polymerization is done in anoxygen-containing environment, there should be enough photoinitiator toinitiate the polymerization and overcome oxygen inhibition.Photoinitiators may respond rapidly and efficiently to a light sourcewith the production of radicals, cations, and other species that arecapable of initiating a polymerization reaction. The photoinitiatorsused in the present invention may absorb UV light at wavelengths ofabout 200 nanometers (nm) to about 800 nm, in certain embodiments about200 nm to about 350 nm. If the photoinitiator is in the oil phase,suitable types of oil-soluble photoinitiators include benzyl ketals,α-hydroxyalkyl phenones, α-amino alkyl phenones, and acylphospineoxides. Examples of photoinitiators include2,4,6-[trimethylbenzoyldiphosphine] oxide in combination with2-hydroxy-2-methyl-1-phenylpropan-1-one (50:50 blend of the two is soldby Ciba Speciality Chemicals, Ludwigshafen, Germany as DAROCUR® 4265);benzyl dimethyl ketal (sold by Ciba Geigy as IRGACURE 651);α-,α-dimethoxy-α-hydroxy acetophenone (sold by Ciba Speciality Chemicalsas DAROCUR® 1173); 2-methyl-1-[4-(methyl thio)phenyl]-2-morpholino-propan-1-one (sold by Ciba Speciality Chemicals asIRGACURE® 907); 1-hydroxycyclohexyl-phenyl ketone (sold by CibaSpeciality Chemicals as IRGACURE® 184);bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide (sold by CibaSpeciality Chemicals as IRGACURE 819); diethoxyacetophenone, and4-(2-hydroxyethoxy)phenyl-(2-hydroxy-2-methylpropyl) ketone (sold byCiba Speciality Chemicals as IRGACURE® 2959); and Oligo[2-hydroxy-2-methyl-1-[4-(1-methylvinyl) phenyl]propanone] (sold byLamberti spa, Gallarate, Italy as ESACURE® KIP EM.

The dispersed aqueous phase of a HIPE may have water, and may also haveone or more components, such as initiator, photoinitiator, orelectrolyte, wherein in certain embodiments, the one or more componentsare at least partially water soluble.

One component of the aqueous phase may be a water-soluble electrolyte.The water phase may contain from about 0.2% to about 40%, in certainembodiments from about 2% to about 20%, by weight of the aqueous phaseof a water-soluble electrolyte. The electrolyte minimizes the tendencyof monomers, comonomers, and crosslinkers that are primarily oil solubleto also dissolve in the aqueous phase. Examples of electrolytes includechlorides or sulfates of alkaline earth metals such as calcium ormagnesium and chlorides or sulfates of alkali earth metals such assodium. Such electrolyte may include a buffering agent for the controlof pH during the polymerization, including such inorganic counterions asphosphate, borate, and carbonate, and mixtures thereof. Water solublemonomers may also be used in the aqueous phase, examples being acrylicacid and vinyl acetate.

Another component that may be present in the aqueous phase is awater-soluble free-radical initiator. The initiator may be present at upto about 20 mole percent based on the total moles of polymerizablemonomers present in the oil phase. The initiator may be present in anamount of from about 0.001 to about 10 mole percent based on the totalmoles of polymerizable monomers in the oil phase. Suitable initiatorsinclude ammonium persulfate, sodium persulfate, potassium persulfate,2,2′-azobis(N,N′-dimethyleneisobutyramidine)dihydrochloride, and othersuitable azo initiators. To reduce the potential for prematurepolymerization which may clog the emulsification system, addition of theinitiator to the monomer phase may be just after or near the end ofemulsification.

Photoinitiators present in the aqueous phase may be at least partiallywater soluble and may have between about 0.05% and about 10%, and incertain embodiments between about 0.2% and about 10% by weight of theaqueous phase. Lower amounts of photoinitiator allow light to betterpenetrate the HIPE foam, which may provide for polymerization deeperinto the HIPE foam. However, if polymerization is done in anoxygen-containing environment, there should be enough photoinitiator toinitiate the polymerization and overcome oxygen inhibition.Photoinitiators may respond rapidly and efficiently to a light sourcewith the production of radicals, cations, and other species that arecapable of initiating a polymerization reaction. The photoinitiatorsused in the present invention may absorb UV light at wavelengths of fromabout 200 nanometers (nm) to about 800 nm, in certain embodiments fromabout 200 nm to about 350 nm, and in certain embodiments from about 350nm to about 450 nm. If the photoinitiator is in the aqueous phase,suitable types of water-soluble photoinitiators include benzophenones,benzils, and thioxanthones. Examples of photoinitiators include2,2′-Azobis[2-(2-imidazolin-2-yl)propane]dihydrochloride;2,2′-Azobis[2-(2-imidazolin-2-yl)propane]disulfate dehydrate;2,2′-Azobis(1-imino-1-pyrrolidino-2-ethylpropane)dihydrochloride;2,2′-Azobis[2-methyl-N-(2-hydroxyethyl)propionamide];2,2′-Azobis(2-methylpropionamidine)dihydrochloride;2,2′-dicarboxymethoxydibenzalacetone,4,4′-dicarboxymethoxydibenzalacetone,4,4′-dicarboxymethoxydibenzalcyclohexanone,4-dimethylamino-4′-carboxymethoxydibenzalacetone; and4,4′-disulphoxymethoxydibenzalacetone. Other suitable photoinitiatorsthat may be used in the present invention are listed in U.S. Pat. No.4,824,765 (Sperry et al.) issued Apr. 25, 1989.

In addition to the previously described components other components maybe included in either the aqueous or oil phase of a HIPE. Examplesinclude antioxidants, for example hindered phenolics, hindered aminelight stabilizers; plasticizers, for example dioctyl phthalate, dinonylsebacate; flame retardants, for example halogenated hydrocarbons,phosphates, borates, inorganic salts such as antimony trioxide orammonium phosphate or magnesium hydroxide; dyes and pigments;fluorescers; filler pieces, for example starch, titanium dioxide, carbonblack, or calcium carbonate; fibers; chain transfer agents; odorabsorbers, for example activated carbon particulates; dissolvedpolymers; dissolved oligomers; and the like.

The heterogeneous mass comprises enrobeable elements and discrete piecesof foam. The enrobeable elements may be a web such as, for example,nonwoven, a fibrous structure, an air-laid web, a wet laid web, a highloft nonwoven, a needlepunched web, a hydroentangled web, a fiber tow, awoven web, a knitted web, a flocked web, a spunbond web, a layeredspunbond/melt blown web, a carded fiber web, a coform web of cellulosefiber and melt blown fibers, a coform web of staple fibers and meltblown fibers, and layered webs that are layered combinations thereof.

The enrobeable elements may be, for example, conventional absorbentmaterials such as creped cellulose wadding, fluffed cellulose fibers,wood pulp fibers also known as airfelt, and textile fibers. Theenrobeable elements may also be fibers such as, for example, syntheticfibers, thermoplastic particulates or fibers, tricomponent fibers, andbicomponent fibers such as, for example, sheath/core fibers having thefollowing polymer combinations: polyethylene/polypropylene,polyethylvinyl acetate/polypropylene, polyethylene/polyester,polypropylene/polyester, copolyester/polyester, and the like. Theenrobeable elements may be any combination of the materials listed aboveand/or a plurality of the materials listed above, alone or incombination.

The enrobeable elements may be hydrophobic or hydrophilic. Theenrobeable elements may be treated to be made hydrophobic. Theenrobeable elements may be treated to become hydrophilic.

The constituent fibers of the heterogeneous mass may be comprised ofpolymers such as polyethylene, polypropylene, polyester, and blendsthereof. The fibers may be spunbound fibers. The fibers may be meltblownfibers. The fibers may comprise cellulose, rayon, cotton, or othernatural materials or blends of polymer and natural materials. The fibersmay also comprise a super absorbent material such as polyacrylate or anycombination of suitable materials. The fibers may be monocomponent,bicomponent, and/or biconstituent, non-round (e.g., capillary channelfibers), and may have major cross-sectional dimensions (e.g., diameterfor round fibers) ranging from 0.1-500 microns. The constituent fibersof the nonwoven precursor web may also be a mixture of different fibertypes, differing in such features as chemistry (e.g. polyethylene andpolypropylene), components (mono- and bi-), denier (micro denier and >20denier), shape (i.e. capillary and round) and the like. The constituentfibers may range from about 0.1 denier to about 100 denier.

In one aspect, known absorbent web materials in an as-made may beconsidered as being homogeneous throughout. Being homogeneous, the fluidhandling properties of the absorbent web material are not locationdependent, but are substantially uniform at any area of the web.Homogeneity may be characterized by density, basis weight, for example,such that the density or basis weight of any particular part of the webis substantially the same as an average density or basis weight for theweb. By the apparatus and method of the present invention, homogeneousfibrous absorbent web materials are modified such that they are nolonger homogeneous, but are heterogeneous, such that the fluid handlingproperties of the web material are location dependent. Therefore, forthe heterogeneous absorbent materials of the present invention, atdiscrete locations the density or basis weight of the web may besubstantially different than the average density or basis weight for theweb. The heterogeneous nature of the absorbent web of the presentinvention permits the negative aspects of either of permeability orcapillarity to be minimized by rendering discrete portions highlypermeable and other discrete portions to have high capillarity.Likewise, the tradeoff between permeability and capillarity is managedsuch that delivering relatively higher permeability may be accomplishedwithout a decrease in capillarity.

The heterogeneous mass may also include superabsorbent material thatimbibe fluids and form hydrogels. These materials are typically capableof absorbing large quantities of body fluids and retaining them undermoderate pressures. The heterogeneous mass may include such materialsdispersed in a suitable carrier such as cellulose fibers in the form offluff or stiffened fibers.

The heterogeneous mass may include thermoplastic particulates or fibers.The materials, and in particular thermoplastic fibers, may be made froma variety of thermoplastic polymers including polyolefins such aspolyethylene (e.g., PULPEX®) and polypropylene, polyesters,copolyesters, and copolymers of any of the foregoing.

Depending upon the desired characteristics, suitable thermoplasticmaterials include hydrophobic fibers that have been made hydrophilic,such as surfactant-treated or silica-treated thermoplastic fibersderived from, for example, polyolefins such as polyethylene orpolypropylene, polyacrylics, polyamides, polystyrenes, and the like. Thesurface of the hydrophobic thermoplastic fiber may be renderedhydrophilic by treatment with a surfactant, such as a nonionic oranionic surfactant, e.g., by spraying the fiber with a surfactant, bydipping the fiber into a surfactant or by including the surfactant aspart of the polymer melt in producing the thermoplastic fiber. Uponmelting and resolidification, the surfactant will tend to remain at thesurfaces of the thermoplastic fiber. Suitable surfactants includenonionic surfactants such as Brij 76 manufactured by ICI Americas, Inc.of Wilmington, Del., and various surfactants sold under the Pegosperse®trademark by Glyco Chemical, Inc. of Greenwich, Conn. Besides nonionicsurfactants, anionic surfactants may also be used. These surfactants maybe applied to the thermoplastic fibers at levels of, for example, fromabout 0.2 to about 1 g. per sq. of centimeter of thermoplastic fiber.

Suitable thermoplastic fibers may be made from a single polymer(monocomponent fibers), or may be made from more than one polymer (e.g.,bicomponent fibers). The polymer comprising the sheath often melts at adifferent, typically lower, temperature than the polymer comprising thecore. As a result, these bicomponent fibers provide thermal bonding dueto melting of the sheath polymer, while retaining the desirable strengthcharacteristics of the core polymer.

Suitable bicomponent fibers for use in the present invention may includesheath/core fibers having the following polymer combinations:polyethylene/polypropylene, polyethylvinyl acetate/polypropylene,polyethylene/polyester, polypropylene/polyester, copolyester/polyester,and the like. Particularly suitable bicomponent thermoplastic fibers foruse herein are those having a polypropylene or polyester core, and alower melting copolyester, polyethylvinyl acetate or polyethylene sheath(e.g., DANAKLON™, CELBOND™ or CHISSO™ bicomponent fibers). Thesebicomponent fibers may be concentric or eccentric. As used herein, theterms “concentric” and “eccentric” refer to whether the sheath has athickness that is even, or uneven, through the cross-sectional area ofthe bicomponent fiber. Eccentric bicomponent fibers may be desirable inproviding more compressive strength at lower fiber thicknesses. Suitablebicomponent fibers for use herein may be either uncrimped (i.e. unbent)or crimped (i.e. bent). Bicomponent fibers may be crimped by typicaltextile means such as, for example, a stuffer box method or the gearcrimp method to achieve a predominantly two-dimensional or “flat” crimp.

The length of bicomponent fibers may vary depending upon the particularproperties desired for the fibers and the web formation process.Typically, in an airlaid web, these thermoplastic fibers have a lengthfrom about 2 mm to about 12 mm long such as, for example, from about 2.5mm to about 7.5 mm long, and from about 3.0 mm to about 6.0 mm long.Nonwoven fibers may be between 5 mm long and 75 mm long, such as, forexample, 10 mm long, 15 mm long, 20 mm long, 25 mm long, 30 mm long, 35mm long, 40 mm long, 45 mm long, 50 mm long, 55 mm long, 60 mm long, 65mm long, or 70 mm long. The properties of these thermoplastic fibers mayalso be adjusted by varying the diameter (caliper) of the fibers. Thediameter of these thermoplastic fibers is typically defined in terms ofeither denier (grams per 9000 meters) or decitex (grams per 10,000meters). Suitable bicomponent thermoplastic fibers as used in an airlaidmaking machine may have a decitex in the range from about 1.0 to about20 such as, for example, from about 1.4 to about 10, and from about 1.7to about 7 decitex.

The compressive modulus of these thermoplastic materials, and especiallythat of the thermoplastic fibers, may also be important. The compressivemodulus of thermoplastic fibers is affected not only by their length anddiameter, but also by the composition and properties of the polymer orpolymers from which they are made, the shape and configuration of thefibers (e.g., concentric or eccentric, crimped or uncrimped), and likefactors. Differences in the compressive modulus of these thermoplasticfibers may be used to alter the properties, and especially the densitycharacteristics, of the respective thermally bonded fibrous matrix.

The heterogeneous mass may also include synthetic fibers that typicallydo not function as binder fibers but alter the mechanical properties ofthe fibrous webs. Synthetic fibers include cellulose acetate, polyvinylfluoride, polyvinylidene chloride, acrylics (such as Orlon), polyvinylacetate, non-soluble polyvinyl alcohol, polyethylene, polypropylene,polyamides (such as nylon), polyesters, bicomponent fibers, tricomponentfibers, mixtures thereof and the like. These might include, for example,polyester fibers such as polyethylene terephthalate (e.g., DACRON™ andKODEL™), high melting crimped polyester fibers (e.g., KODEL™ 431 made byEastman Chemical Co.) hydrophilic nylon (HYDROFIL™), and the like.Suitable fibers may also hydrophilized hydrophobic fibers, such assurfactant-treated or silica-treated thermoplastic fibers derived from,for example, polyolefins such as polyethylene or polypropylene,polyacrylics, polyamides, polystyrenes, polyurethanes and the like. Inthe case of nonbonding thermoplastic fibers, their length may varydepending upon the particular properties desired for these fibers.Typically they have a length from about 0.3 to 7.5 cm, such as, forexample from about 0.9 to about 1.5 cm. Suitable nonbondingthermoplastic fibers may have a decitex in the range of about 1.5 toabout 35 decitex, such as, for example, from about 14 to about 20decitex.

The backsheet 207 may be positioned adjacent a garment-facing surface ofthe absorbent structure 205 and may be joined thereto by attachmentmethods (not shown) such as those well known in the art. For example,the backsheet 207 may be secured to the absorbent structure 205 by auniform continuous layer of adhesive, a patterned layer of adhesive, oran array of separate lines, spirals, or spots of adhesive.Alternatively, the attachment methods may comprise using heat bonds,pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any othersuitable attachment methods or combinations of these attachment methodsas are known in the art. Forms of the present disclosure are alsocontemplated wherein the absorbent core 205 is not joined to thebacksheet 207, the topsheet 203, or both.

The backsheet 207 may be impervious, or substantially impervious, toliquids (e.g., urine) and may be manufactured from a thin plastic film,although other flexible liquid impervious materials may also be used. Asused herein, the term “flexible” refers to materials which are compliantand will readily conform to the general shape and contours of the humanbody. The backsheet 207 may prevent, or at least inhibit, the exudatesabsorbed and contained in the absorbent core 205 from wetting articlesof clothing which contact the feminine pad 10 such as undergarments.However, the backsheet 207 may permit vapors to escape from theabsorbent structure 205 (i.e., is breathable). Thus, the backsheet 205may comprise a polymeric film such as thermoplastic films ofpolyethylene or polypropylene. A suitable material for the backsheet 207is a thermoplastic film having a thickness of from about 0.012 mm (0.5mil) to about 0.051 mm (2.0 mils), for example. Any suitable backsheetknown in the art may be utilized with the present invention.

The topsheet 203 is positioned adjacent a body-facing surface of theabsorbent structure 205 and may be joined thereto and to the backsheet207 by attachment methods (not shown) such as those well known in theart. Suitable attachment methods are described with respect to joiningthe backsheet 207 to the absorbent structure 205. The topsheet 203 andthe backsheet 207 may be joined directly to each other in the femininepad periphery and may be indirectly joined together by directly joiningthem to the absorbent structure 205 by the attachment methods.

The topsheet 203 may be compliant, soft feeling, and non-irritating tothe wearer's skin. Further, the topsheet 203 may be liquid perviouspermitting liquids (e.g., urine) to readily penetrate through itsthickness. Some suitable examples of topsheet materials include films,nonwovens, laminate structures including film/nonwoven layers, film/filmlayers, and nonwoven/nonwoven layers. Other exemplary topsheet materialsand designs are disclosed in provisional patent application Ser. No.62/177,405 (filed Mar. 13, 2015), 62/168,199 (filed Mary 29, 2015), and62/190,000 (filed Jul. 8, 2015).

The covers of the barrier cuffs of the present invention can be made ofvarying types of nonwovens of different MD and CD flexibility. The covercan be bonded to the topsheet of the absorbent article, such as, forexample, by a slot coated stripe of adhesive, glue beads, ultrasonicsealing, or other suitable bonding agents. In certain forms of thepresent invention, the cover can be bonded to the backsheet at the sideedges 22 and 24 (see FIG. 1) of the pad, such as, for example, using acrimp or other suitable bonding agents, such as, for example, adhesive.

In addition, in certain forms of the present invention, a portion 261(See FIG. 2A) of the barrier cuff having the elastic members can then befolded back on itself and the folded back portion 261 can be gluedcontinuously along the pad length. The folded back portion can then bebonded intermittently at the ends of the pad to the topsheet to preventthe barrier cuff from lifting at the ends of the pad while allowing itto lift in the central portion of the pad.

Elastic members may comprise any suitable elastic material. Somesuitable examples include Spandex™ or other similar polyurethanes,natural or synthetic rubber, styrene block copolymers, metallocenepolyolefins, Lycra™, or any other suitable elastomer materials known inthe art. Preferably the elastic member is durable for ease of processingand for during the use of the article and exhibits excellent elasticity(recovery after strain) even under strains as high as 400%.

Additionally, the elastic members of the present disclosure may compriseany suitable dtex. Some exemplary dtex's are provided in the specificexamples herein. In other forms, the elastic members may comprise a dtexof 680 or less. In some forms, the elastic members may have a dtexbetween 680 and 470, specifically including all numbers within the rangeand any ranges created thereby.

Referring back to FIG. 1, to construct the barrier cuffs 230A and 230B,the elastic members can be put under tension by stretching them. Incertain forms of the present invention, each of the elastic members canbe stretched to about 30% to about 400% engineering strain, such as, forexample, from about 40% to about 300% engineering strain. In some forms,the engineering strain on the elastic members can be from about 45% toabout 200%, from about 50% to about 150%, from about 55% to about 120%,from about 60% to about 90%, specifically including any numbers withinthese ranges and any ranges created thereby. In one example, the elasticcan have a length of x and can be stretched an additional 1x such thatthe final stretched length of the elastic is 2x. In another example, theelastic can have a length of x and can be stretched an additional 2xsuch that the final stretched length of the elastic is 3x. In yetanother example, the elastic can have a length of x and can be stretchedan additional 1.5x such that the final stretched length is 2.5x. Theelastic members are then attached to the cover, such as, for example, bygluing using elastic wrap adhesive or other suitable adhesives. Incertain forms of the present invention, the glued length of the elasticmembers can be any suitable length, such as, for example, from about 100to about 500 mm, from about 100 to about 400 mm, from about 100 to about300 mm, from about 100 to about 200 mm, from about 150 to about 200 mm,or any other suitable length. When the elastic members are cut at theends of the pad, they attempt to contract to their relaxed dimension. Intypical diaper applications, the elastic members of their respectivebarrier cuffs are subjected to an engineering strain of over 200%.

In some forms of the present invention, the elastic members may compriseslow recovery elastic materials. For example, in some forms of thepresent invention the elastic members may exhibit a normalized unloadforce of greater than about 0.16 N/(g/m) at 37° C. as measured by theTwo Cycle Hysteresis Test. Normalized unload forces of less than about0.12 N/(g/m) at 37° C. are believed to be insufficient for use as anelastomer within absorbent articles. In some specific forms of thepresent invention, the elastic members exhibit a normalized unload forceof greater than about 0.24 N/(g/m) at 37° C.

In contrast, the elastic members of the current invention exhibit apercent of initial strain of about 10% or greater after 15 seconds ofrecovery at 22° C., as measured by the Post Elongation Recovery Test. Inother forms of the present invention, the elastic members exhibit apercent of initial strain of about 20% or greater after 15 seconds ofrecovery at 22° C. In other suitable forms of the present invention, theelastic members exhibit a percent of initial strain of about 30% orgreater after 15 seconds of recovery at 22° C. In other suitable forms,the elastic members exhibit a percent of initial strain of about 40% orgreater after 15 seconds of recovery at 22° C.

Furthermore, the elastic members of the present invention may exhibit aspecified percent of initial strain at 22° C. after 30 seconds, 60seconds, or three minutes of recovery. In certain forms, the elasticmembers may exhibit a percent of initial strain at 22° C. after 30seconds of recovery of about 10% or greater. Alternatively, the elasticmembers may exhibit a percent of initial strain at 22° C. after 30seconds of recovery about 15% or greater. In other forms of the presentinvention, the elastic members may exhibit a percent of initial strainat 22° C. after 60 seconds of recovery of about 10% or greater.

The elastic members may exhibit temperature responsiveness. In certainforms of the present invention, the elastic members exhibit a percent ofinitial strain at 32° C. after a specified amount of recovery time thatis less than the percent of initial strain exhibited at 22° C. after thesame recovery time. In one particular form of the present invention,temperature responsive elastic members may exhibit a reduction in apercent of initial strain after 15 seconds at 32° C. as compared to thepercent of initial strain exhibited after 15 seconds at 22° C. (i.e.,[percent of initial strain after 15 seconds of recovery at 22°C.]−[percent of initial strain after 15 seconds of recovery at 32° C.]).In some forms of the present invention, the difference is equal to orgreater than 5%. In other forms of the present invention, the elasticmembers may exhibit a difference in the percent of initial strain after15 seconds at 22° C. compared to after 15 seconds at 32° C. equal to orgreater than 10%, 20%, 30%, or, alternatively, 40%. It is believed thatelastic members exhibiting temperature responsiveness may furtherfacilitate pad application. When the feminine pad is applied at aboutroom temperature (i.e., approximately 22° C.), the elastic members mayexhibit a relatively high percent of initial strain for a prescribedperiod of time, which allows the wearer to apply the pad. Uponapplication of the pad, the temperature of the elastic members will riseas a result of being in close proximity to the wearer's skin. As thetemperature of the elastic members increases and nears skin temperature(i.e., approximately 32° C.), the percent of initial strain is reduced.Temperature responsiveness allows for application of the pad without“snap-back” while providing for increased recovery after application.Slow recovery elastics are discussed further in U.S. Pat. Nos.7,717,893; 8,419,701; and 7,905,872.

In some forms of the present invention, the feminine pads may comprisewings. Wings can provide additional leakage protection for the femininepad and can help secure the pad to the underwear of the user. Anysuitable wing configuration known in the art may be utilized.

All the components can be adhered together with adhesives, including hotmelt adhesives, as is known in the art. The adhesive can be FindlayH2128 UN or Savare PM 17 and can be applied using a Dynafiber HTWsystem.

Referring to FIGS. 1 and 2A, in use, the pad can be held in place by anysupport or attachment suitable for such purposes. In certain forms ofthe present invention, the pad is placed in the user's undergarment orpanty and secured thereto by the fastening adhesive 211. The fasteningadhesive 211 secures the pad in the crotch portion of the user's panty.A portion or all of the garment-facing surface 20B of the chassis 20 iscoated with fastening adhesive 211. Any adhesive or glue suitable forsuch purposes can be used for the fastening adhesive 211 herein, suchas, for example, using pressure-sensitive adhesive. Suitable adhesivesinclude, for example, Century A-305-IV manufactured by the CenturyAdhesives Corporation of Columbus, Ohio; and Instant Lock 34-2823manufactured by the National Starch and Chemical Company of Bridgewater,N.J. Suitable adhesive fasteners are also described in U.S. Pat. No.4,917,697. Before the absorbent article is placed in use, thepressure-sensitive adhesive is typically covered with a removablerelease liner in order to keep the adhesive from drying out or adheringto a surface other than the crotch portion of the panty prior to use.Suitable release liners are also described in U.S. Pat. Nos. 4,917,697and 4,556,146. Any commercially available release liners commonly usedfor such purposes can be utilized herein. Non-limiting examples ofsuitable release liners are BL30MG-A Silox E1/0 and BL30MG-A Silox 4P/Oboth of which are manufactured by the Akrosil Corporation of Menasha,Wis. The pad can be used by removing the release liner and thereafterplacing the absorbent article in a panty so that the adhesive contactsthe panty. The adhesive maintains the absorbent article in its positionwithin the panty during use. The release liner can also be a wrapperthat can individually package the pad.

Examples

Samples 1-2C were constructed in accordance with the present disclosure.Samples 3-7 are products which are currently available on the market.

Sample 1: A feminine pad approximately 270 mm long and comprising 2 foldlines. The first fold line being approximately 92 mm from the first endedge, and the second fold line being approximately 73 mm from the secondend edge. The feminine pad further comprises:

-   -   (1) a nonwoven topsheet having a basis weight of 18 gsm of 50/50        polypropylene/polyethylene core/sheath configuration bicomponent        fibers;    -   (2) a nonwoven secondary topsheet having a basis weight of 75        gsm and comprising 25 percent hollow spiral polyethylene        terephthalate fibers of 10 dtex, 40 percent polypropylene fibers        of 6.7 dtex, and 35 percent viscose rayon trilobal fibers of 3.3        dtex; the nonwoven secondary topsheet had a length of 218 mm and        a width of 95 mm and was wrapped around item (4) such that        opposite ends of the nonwoven secondary topsheet were positioned        at the bottom of the item (4) and such that the nonwoven        secondary topsheet was centered on item (4);    -   (3) an absorbent material—AGM at 1.8 grams distributed along the        length and width of item (4);    -   (4) an Airlaid material having a basis weight of 345 gsm having        pulp (treated and untreated), AGM (about 35% of the mass), as        well as PET/PE core sheath bi-component fibers (which are        thermally bonded) and latex binder. The whole material is        embossed for further material stability; 59 mm wide and 218 mm        long.    -   (5) a backsheet which is 14 gsm polypropylene film;    -   (6) barrier cuff—nonwoven first cover/second cover each having a        basis weight of 14 gsm (glued continuously in MD to the topsheet        at a spacing of 40 mm) and having an inner to inner spacing of        about 34 mm (continuing to CD edges);    -   (7) barrier—cuff—elastic members of Lycra®—2 strands per cuff        each having 470 dtex stretched about 60% each and glued for 120        mm (attachment approximately 85 mm from leading and 65 mm from        trailing edge). Inner to inner elastic spacing of about 41 mm        and spacing of about 4 mm between each strand in each cuff.        Sample 2A: A feminine pad approximately 400 mm long and        comprising 2 fold lines. The first fold line being approximately        135 mm from the first end edge, and the second fold line being        approximately 116 mm from the second end edge. The feminine pad        further comprises:    -   (1) a nonwoven topsheet having a basis weight of 18 gsm of 50/50        polypropylene/polyethylene core/sheath configuration bicomponent        fibers;    -   (2) a nonwoven secondary topsheet having a basis weight of 75        gsm and comprising 25 percent hollow spiral polyethylene        terephthalate fibers of 10 dtex, 40 percent polypropylene fibers        of 6.7 dtex, and 35 percent viscose rayon trilobal fibers of 3.3        dtex; the nonwoven secondary topsheet had a length of 339 mm and        a width of 114 mm and was wrapped around item (4) such that        opposite ends of the nonwoven secondary topsheet were positioned        at the bottom of the item (4) and such that the nonwoven        secondary top sheet was centered on item (4);    -   (3) an absorbent material—AGM at 5.7 grams distributed along the        length and the width of item (4);    -   (4) an Airlaid material having a basis weight of 345 gsm having        pulp (treated and untreated), AGM (about 35% of the mass), as        well as PET/PE core sheath bi-component fibers (which are        thermally bonded) and latex binder. The whole material is        embossed for further material stability; 79 mm wide and 339 mm        long.    -   (5) a backsheet which is 14 gsm polypropylene film;    -   (6) barrier cuff—nonwoven first cover/second cover each having a        basis weight of 15 gsm (glue continuously in MD to the topsheet        with a spacing of 72 mm and glued intermittently for about 63 mm        at the ends of the product with a 60 mm spacing) and having an        inner to inner spacing of about 54 mm (continuing to CD edges);    -   (7) barrier cuff—elastic members of Lycra®—2 strands per cuff        each having 470 dtex stretched about 80% each and glued for 246        mm (attachment approximately 77 mm from each end). Inner to        inner elastic spacing of about 61 mm and spacing of about 4 mm        between each strand in each cuff.        Sample 2B: A feminine pad being approximately 348 mm long and        comprising 2 fold lines. The first fold line being approximately        118 mm from the first end edge, and the second fold line being        approximately 99 mm from the second end edge). The feminine pad        further comprising:    -   (1) a nonwoven topsheet having a basis weight of 18 gsm of 50/50        polypropylene/polyethylene core/sheath configuration        bi-component fibers;    -   (2) a nonwoven secondary topsheet having a basis weight of 75        gsm and comprising 25 percent hollow spiral polyethylene        terephthalate fibers of 10 dtex, 40 percent polypropylene fibers        of 6.7 dtex, and 35 percent viscose rayon trilobal fibers of 3.3        dtex; the nonwoven secondary topsheet had a length of 288 mm and        a width of 104 mm and was wrapped around item (4) such that        opposite ends of the nonwoven secondary topsheet were positioned        at the bottom of the item (4) and such that the nonwoven        secondary topsheet was centered on item (4);    -   (3) an absorbent material—AGM at 4.8 grams distributed along the        length and width of item (4);    -   (4) an Airlaid material having a basis weight of 345 gsm having        pulp (treated and untreated), AGM (about 35% of the mass), as        well as PET/PE core sheath bi-component fibers (which are        thermally bonded) and latex binder. The whole material is        embossed for further material stability; 69 mm wide and 288 mm        long.    -   (5) a backsheet which is 14 gsm polypropylene film;    -   (6) barrier cuff—nonwoven first cover/second cover each having a        basis weight of 15 gsm (glue continuously in MD to the topsheet        with a spacing of 62 mm and glued intermittently for about 63 mm        at the ends of the product with a 50 mm spacing) and having an        inner to inner spacing of about 44 mm (continuing to CD edges);    -   (7) barrier cuff—elastic members of Lycra®—2 strands per cuff        each having 470 dtex stretched about 80% each and glued for 120        mm (attachment approximately 85 mm from the first end edge and        65 mm from second end edge). Inner to inner elastic spacing of        about 51 mm and spacing of about 4 mm between each strand in        each cuff.        Sample 2C: A feminine pad being approximately 348 mm long and        comprising 2 fold lines. The first fold line being approximately        118 mm from the first end edge, and the second fold line being        approximately 99 mm from the second end edge). The feminine pad        further comprising:    -   (1) a nonwoven topsheet having a basis weight of 18 gsm of 50/50        polypropylene/polyethylene core/sheath configuration        bi-component fibers;    -   (2) a nonwoven secondary topsheet having a basis weight of 75        gsm and comprising 25 percent hollow spiral polyethylene        terephthalate fibers of 10 dtex, 40 percent polypropylene fibers        of 6.7 dtex, and 35 percent viscose rayon trilobal fibers of 3.3        dtex; the nonwoven secondary topsheet had a length of 288 mm and        a width of 69 mm; and was wrapped around item (4) such that        opposite ends of the nonwoven secondary topsheet were positioned        at the bottom of the item (4) and such that the nonwoven        secondary top sheet was centered on item (4);    -   (3) an absorbent material—AGM at 7.2 grams distributed along the        length and width of item (4);    -   (4) a nonwoven (SMS configuration) material of polypropylene        having a basis weight of 10 gsm, a length of 288 mm and a width        of 69 mm;    -   (5) an Airlaid material having a basis weight of 135 gsm having        untreated pulp as well as PET/PE core sheath bi-component fibers        (which are thermally bonded) and latex binder. The whole        material is about 69 mm wide and 288 mm long.    -   (6) a backsheet which is 14 gsm polypropylene film;    -   (7) barrier cuff—nonwoven first cover/second cover each having a        basis weight of 15 gsm (glue continuously in MD to the topsheet        with a spacing of 62 mm and glued intermittently for about 63 mm        at the ends of the product with a 50 mm spacing) and having an        inner to inner spacing of about 44 mm (continuing to CD edges);    -   (8) barrier cuff—elastic members of Lycra®—2 strands per cuff        each having 470 dtex stretched about 80% each and glued for 120        mm (attachment approximately 85 mm from the first end edge and        65 mm from second end edge). Inner to inner elastic spacing of        about 51 mm and spacing of about 4 mm between each strand in        each cuff.

Each of the above materials for each of the samples was adhesivelyjoined to adjacent layers utilizing conventional adhesives withconventional adhesive application techniques at conventional adhesivebasis weights respectively. With conventional basis weight andapplications in absorbent articles, adhesives are believed to contributeto a very small extent of article stiffness as opposed to othercomponents of the article. However, topsheet and the backsheet werethermally bonded to form the periphery of the article.

Sample 3: Always Discreet Moderate Absorbency, Regular Length. Sample 4:Always Discreet Ultimate Absorbency, Long Length. Sample 5: Poise PadsModerate Absorbency, Regular Length. Sample 6: Poise Overnight Pads,Ultimate Absorbency Long Length. Sample 7: Poise Thin Shape Pads,Moderate Absorbency.

Data obtained from the above Samples regarding flexibility of thearticle is provided in Table 1. Samples 1 through 4 comprise barriercuffs which have covers which are discrete and are attached to theirrespective top sheets. The anchor points for the covers and the elasticmembers for Samples 1 through 2C are inboard of the side edges of theirrespective absorbent cores. Samples 5 and 6 comprise barrier cuffs whichcomprise a portion of the topsheet and the backsheet. Anchor points forthe elastic member are outboard of their respective absorbent cores.Sample 7 comprises barrier cuffs having discrete covers attached to thebacksheet. Its elastic members are disposed outboard of the absorbentcore.

TABLE 1 Sample No. Property 1 2A 2B 2C 3 4 5 6 7 Average Pad Thickness4.1 4.6 4.3 3.8 4.7 5.2 7.0 11.9 4.0 Central (mm) Average Pad Length(mm) 269.5 400.3 349.5 351.4 272.5 400.5 274.0 398.2 258.5 EMS (mm) 53.574.5 66.2 66.8 51.5 67.5 92.2 135.5 109.3 Average Core Width @ 63.0 82.573.8 69.6 65.3 84.5 74.2 79.2 65.2 Longitudinal Center (mm) Average CoreWidth @ 62.0 82.7 74.7 70.0 68.3 89.7 73.0 103.2 73.5 Front Fold (mm)Average Core Width @ Back 62.2 82.8 74.8 69.8 65.7 87.7 73.2 89.8 79.5Fold (mm) WER @ Longitudinal Center 1.2 1.1 1.1 1.0 1.3 1.3 0.8 0.6 0.6WER @ Front Fold 1.2 1.1 1.1 1.0 1.3 1.3 0.8 0.8 0.7 WER @ Back Fold 1.21.1 1.1 1.0 1.3 1.3 0.8 0.7 0.7 LER 5.0 5.4 5.3 5.3 5.3 5.9 3.0 2.9 2.4

Table 2 includes data with regard to the MD flexibility force and the CDflexibility force. Additionally, Table 2 include data with regard to theflexibility factor of the article. The flexibility factor takes intoconsideration the MD and CD flexibility. The flexibility factor isdetermined by the following equation.

${{flexibility}\mspace{14mu} {factor}} = \sqrt{\begin{matrix}{\left( {{Average}\mspace{14mu} {CD}\mspace{14mu} {Peak}\mspace{14mu} {Load}\mspace{14mu} {MD}\mspace{14mu} {flexibility}} \right)^{2} +} \\\left( {{Average}\mspace{14mu} {MD}\mspace{14mu} {Peak}\mspace{14mu} {{Load}{CD}}\mspace{14mu} {flexibility}} \right)^{2}\end{matrix}}$

As noted previously, there are several factors which impact productcurling during application. For example, the elastic forces exerted onthe article by the barrier cuffs, as discussed previously is a factor.Elastic member engineering strain and elastic denier are also factors.Glue in length of the elastic member which extends from an outboard edgeof an adhesive to an outboard edge of an adhesive in the firstattachment zone and second attachment zone, respectively. Stiffness ofthe article as discussed previously, is also a factor. Core stiffness,e.g. all materials between the topsheet and backsheet, is believed to bethe primary driver of article stiffness in both the MD and CD. Whileother materials like glues can play a roll, these materials are believedto contribute to article stiffness to a much lesser extent than that ofthe absorbent core.

TABLE 2 Sample No. Property 1 2A 2B 2C 3 4 5 6 7 Average CD Peak Load112.2 130.3 108.7 35.9 170.6 261.5 126.7 506.4 36.6 (grams force)Average MD Peak Load 162.8 166.3 134.7 45.2 177.7 281.4 150.7 595.0 45.1(grams force) Flexibility factor (FF) 197.7 211.3 173.1 57.7 246.4 384.2196.9 781.3 58.1

Table 3 includes data with regard to the curl of the measured pads alongwith other measured features. The data in Table 3 includes spacing ofthe barrier cuffs, pad curl regarding front/back and left/right.

TABLE 3 Sample No. Property 1 2A 2B 2C 3 4 5 6 7 FL2 (mm) 4.9 5.8 4.84.5 4.7 5.3 3.9 7.3 5.7 FR2 (mm) 4.5 5.0 4.9 4.5 4.5 5.3 4.7 7.7 5.8RL2(mm) 3.8 5.4 4.1 4.0 4.3 5.4 3.7 6.6 4.7 RR2 (mm) 3.8 4.9 4.1 4.1 4.35.3 5.2 6.5 5.8 (FL2 + FR2)/2 (mm) 4.7 5.4 4.8 4.5 4.6 5.3 4.3 7.5 5.8(RL2 + RR2)/2 (mm) 3.8 5.1 4.1 4.1 4.3 5.4 4.5 6.5 5.2 FL (mm) 6.0 6.95.7 5.5 6.0 6.0 7.5 11.6 15.5 FR (mm) 5.0 6.6 5.2 5.0 5.8 5.7 7.3 11.88.8 RL (mm) 5.8 6.1 5.7 5.5 5.8 6.7 7.2 12.3 16.5 RR (mm) 5.5 6.2 5.65.8 6.0 6.8 8.0 13.7 11.3 (FL + FR)/2(mm) 5.5 6.8 5.5 5.2 5.9 5.8 7.411.7 12.2 (RL + RR)/2(mm) 5.7 6.1 5.6 5.6 5.9 6.7 7.6 13.0 13.9 FPC (mm)0.8 1.4 0.6 0.7 1.3 0.5 3.1 4.2 6.4 RPC (mm) 1.9 1.0 1.5 1.6 1.6 1.4 3.16.4 8.6 APC (mm) 1.3 1.2 1.1 1.1 1.4 1.0 3.1 5.3 7.5

In some forms, the average of the front pad curl (FPC) and rear pad curl(RPC)—average pad curl (APC)—in mm versus the average CD peak load ingrams force is shown in the graph shown in FIG. 9. In some forms, theAPC may satisfy the following equation with regard to CD peak load.

APC≦(−0.038Average CD Peak Load+7.1354)

Line 900 is provided for ease of visualization.

In such forms, the APC may be less than about 7.0 mm, less than about6.0 m, less than about 5.0 mm, less than about 4.0 mm, or less thanabout 3.0 mm, specifically including all numbers within these ranges andany ranges created thereby. In one specific example, the APC may be frombetween about 0.5 mm to about 3.0 mm or from about 1.0 mm to about 2.5mm, specifically including all numbers within these ranges and anyranges created thereby. In such forms, the cross directional peak loadmay be less than about 188 grams force, less than about 170 grams force,less than about 160 grams force, less than about 130 grams force, orless than about 120 grams force, specifically including all numberswithin the range and any ranges created thereby. In one specificexample, the cross directional peak load may be from between about 30grams force to about 188 grams force or from about 35 grams force toabout 170 grams force, specifically including all numbers within theseranges and any ranges created thereby.

In some forms, the APC in mm versus the Flexibility Factor is shown inthe graph of FIG. 10. In some forms, the APC may satisfy the followingequation with regard to the flexibility factor.

APC≦(−0.0338 FF+8.7879)

Line 1000 is provided for ease of visualization.

In such forms, the APC may be less than about 9.0 mm, less than about8.0 mm, less than about 7.0 mm, less than about 6.0 mm, less than about5.0 mm, less than about 4.0 mm or less than about 3.0 mm, specificallyincluding all numbers within these ranges and any ranges createdthereby. In one specific example, the APC may be from between about 0.5mm to about 3.0 mm or from about 1.0 mm to about 2.5 mm, specificallyincluding all numbers within these ranges and any ranges createdthereby. In such forms, the flexibility factor may be less than about260, 250, 240, 230, 220, 210, 200, or 190, specifically including allnumbers within these ranges and any ranges created thereby. In onespecific example, the flexibility factor may be from between about 30 toabout 260, 40 to 240, or 50 to 220, specifically including all numberswithin these ranges and any ranges created thereby.

Based on the data above, in some forms, the APC may be less than about3.0 mm or less than about 2.0 mm, specifically including all numberswithin these ranges and any ranges created thereby. In some specificexamples, the APC may be between about 0.5 mm to about 2.5 mm or frombetween about 1.0 mm to about 2.0 mm, specifically including all numberswithin these ranges and any ranges created thereby. In such forms, theflexibility factor may be less than about 240, 230, 220, or 212specifically including any numbers within these ranges and any rangescreated thereby. In one specific example, a disposable absorbent articlemay comprise a flexibility factor of between about 50 to about 220,specifically including all numbers within the range and any rangescreated thereby. In addition to the flexibility factor or independentlytherefrom, in such forms, the average cross directional peak load may beless than about 160 grams force, less than about 150 grams force, orless than about 120 grams force, specifically including all numberswithin these ranges and any ranges created thereby. In one specificexample, the average cross directional peak force may be from betweenabout 20 grams force to about 160 grams force, about 30 grams force toabout 150 grams force, or between about 35 grams force to about 135grams force, specifically including all numbers within the range and anyranges created thereby. Similarly, in addition to the flexibility factorand/or the cross directional peak load or independently thereof, in suchforms, the average machine direction peak load may be less than about170 grams force, less than about 160, less than about 150, or less thanabout 140, specifically including all numbers within these ranges andany ranges created thereby. In one example, the average machinedirection peak load may be from between about 40 to about 170 gramsforce, specifically including all numbers within the range and anyranges created thereby.

In yet other forms, the APC may be less than about 7.5 mm, less than 7.0mm, less than 4.0 mm, or less than 3.0 mm, specifically including allnumbers within these ranges and any ranges created thereby. In onespecific example, the APC may be from between about 0.5 mm to about 4.0mm or from about 1.0 mm to about 3.0 mm, specifically including allnumbers within these ranges and any ranges created thereby. In suchforms, the flexibility factor may be less than 190, 180, 170, 160, or150, specifically including all numbers within these ranges and anyranges created thereby. In one specific example, the flexibility factormay be from between about 50 to about 190, specifically including allnumbers within this range and any ranges created thereby. In addition tothe flexibility factor or independently therefrom, in such forms, theaverage cross directional peak load may be less than about 120 gramsforce less than about 115 grams force, or less than about 110 gramsforce, specifically including all numbers within these ranges or anyranges created thereby. In one specific example, the average crossdirectional peak load may be from between about 30 grams force to about120 grams force or from about 35 grams force to about 115 grams force,specifically including all numbers within these ranges and any rangescreated thereby.

Still in other forms, the APC may be less than about 3.0 mm or less thanabout 2.0 mm, specifically including all numbers within these ranges andany ranges created thereby. In some specific examples, the APC may bebetween about 0.5 mm to about 2.5 mm or from between about 1.0 mm toabout 2.0 mm, specifically including all numbers within these ranges andany ranges created thereby. In such forms, the cross directional peakload may be less than about 160 grams force, less than about 150 gramsforce, less than about 140 grams force, less than 130 grams force, orless than about 120 grams force, specifically including all numberswithin these ranges and any ranges created thereby. In one specificexample, the average cross directional peak force may be from betweenabout 20 grams force to about 160 grams force, about 30 grams force toabout 150 grams force, or between about 35 grams force to about 135grams force, specifically including all numbers within the range and anyranges created thereby. In such forms, the flexibility factor may beless than about 380, less than about 370, less than about 350, less thanabout 300, less than about 280, less than about 250, or less than about220, specifically including all numbers within these ranges and anyranges created thereby. In one specific example, a disposable absorbentarticle may comprise a flexibility factor of between about 30 to about380, 50 to about 340, 55 to about 330, or from about 40 to 220,specifically including all numbers within the range and any rangescreated thereby.

Test Methods: Basis Weight Method

Basis weights of materials described herein may be determined by severalavailable techniques, but a simple representative technique involvestaking an absorbent article or other consumer product, removing anyelastic which may be present and stretching the absorbent article orother consumer product to its full length. A punch die having an area of45.6 cm² is then used to cut a piece of the material to be analyzed(e.g., topsheet or backsheet) from the approximate center of theabsorbent article or other consumer product in a location which avoidsto the greatest extent possible any adhesive which may be used to fastenthe material to any other layers which may be present and removing thematerial from other layers (using cryogenic spray, such as Cyto-Freeze,Control Company, Houston, Tex., if needed). The sample is then weighedand dividing by the area of the punch die yields the basis weight of thematerial. Results are reported as a mean of 5 samples to the nearest 0.1cm².

Pad Curl and Other Measurements

Samples are conditioned at 23° C.±2° C. and 50%±2% relative humidity for2 hours prior to testing. The test is run under the same environmentalconditions. All linear measurements are made using a calibrated steelmetal ruler traceable to NIST or other standards organization. Calipermeasurements are made using a Schiefer Standard Spring Compressometer(available from Frazier Precision Instrument Co., Hagerstown Md.) orequivalent. The compressometer was used with a 4.75 mm diameter ball asthe foot. Herein front, rear, left and right refer to the productsorientation on the wearer's body.

The article is removed from its wrap and if present, the release paperof the removed article to expose the panty fastening adhesive (PFA).Apply talc powder to the PFA on the back sheet to mitigate tackiness.Suspend the article vertically by its front leading edge. Attach a 500g±1 g weight to the rear leading edge allowing the article to hangfreely. After 30 sec measure the length of the article along thelongitudinal centerline of the article to the nearest 0.1 mm and recordas the Article Length (AL).

The article is mounted on a flat metal plate approximately 3 mm inthickness, and length and width dimensions are larger than the article.Using 2.54 cm wide masking tape, secure the article to the center of themetal plate. The tape is attached along the longitudinal centerline atfront edge with 1 cm of the tape overlapping the articles edge. In likefashion the rear edge is secured to the plate such that the article isextended to the previously measured AL for that article. After mountingthe article caliper measurements are done without undue delay.

Caliper measures for the Front Pad Curl (FPC) are made on the front 30%of the article. The front of the article corresponds to that portion ofthe article that would be associated with the anterior portion of thebody during normal use. Place the metal plate under the foot. Slowlylower the foot until the foot visually touches the plate. Zero the lowercaliper gauge of the compressometer. Next place the front left corner ofthe article under the foot. Visually select a site within 1 cm of theleft distal side of the absorbent body that is the greatest elevationfrom the metal plate. Slowly lower the foot until the foot visuallytouches the top sheet of the article and record the caliper (FL) to thenearest 0.1 mm. Move the mounted article so that the front right corneris under the foot. Visually select a site within 1 cm of the rightdistal side of the absorbent body that is the greatest elevation fromthe metal plate. Slowly lower the foot until the foot visually touchesthe top sheet and record the caliper (FR) to the nearest 0.1 mm. Take apiece of masking tape longer than the width of the article, and place itacross the article perpendicular to longitudinal centerline of thearticle and aligned immediately inboard of the absorbent body to tackdown any pad curl. Again place the front left corner of the articleunder the foot. Select a site that is 5 mm inboard of the masking tapeand 5 mm inboard of the edge of the absorbent body. Slowly lower thefoot until the foot visually touches the top sheet and record thecaliper (FL2) to the nearest 0.1 mm. Move the mounted article so thatthe front right corner is under the foot. Select a site 5 mm inboard ofthe masking tape and 5 mm inboard of the edge of the absorbent body.Slowly lower the foot until the foot visually touches the top sheet andrecord the caliper (FR2) to the nearest 0.1 mm. Calculate the Front PadCurl (FPC) as [((FL+FR)/2)−(FL2+FR2)/2] and report to the nearest 0.1mm. The Rear Pad Curl (RPC) is measured and calculated in like fashion(on the rear 30% of the article) and also record to the nearest 0.1 mm.Calculate the Rear Pad Curl (RPC) as [((RL+RR)/2)−(RL2+RR2)/2] andreport to the nearest 0.1 mm. Calculate Average Pad Curl as (FPC+RPC)/2and report to the nearest 0.1 mm.

Remove the article from the metal plate and remount the article at thecorrect AL extension to a light box that is larger than the size of thearticle. Mark the intersection of the longitudinal and lateralcenterline of the article. Using a calibrated ruler measure the distancealong the lateral centerline between the outermost elastic member leftof the longitudinal centerline to the outermost elastic member right ofthe longitudinal centerline to the nearest 0.1 mm. Record as the ElasticMember Spacing (EMS). Also measure the width of the absorbent body alongthe lateral centerline and record to the nearest 0.1 mm. Record as theCore Width (CW). Calculate a Length to Elastic Ratio (LER) by dividingthe AL by the EMS and record to the nearest 0.1 mm. Calculate a Width toElastic Ratio (WER) by dividing the CW by the EMS and record to thenearest 0.1 mm.

Repeat measurements on a total of six replicate pads. Calculate thearithmetic mean for all Front Pad Curl (FPC), Rear Pad Curl (RPC),Length to Elastic Ratio (LER), and Width to Elastic Ratio (WER). Reportall values to the nearest 0.1 mm.

MD/CD Flexibility Equipment Preparation:

The bending properties of a sample are measured on a constant rate ofextension tensile tester (a suitable instrument is the MTS Allianceusing Testworks 4.0 Software, as available from MTS Systems Corp., EdenPrairie, Minn.) using a load cell for which the forces measured arewithin 10% to 90% of the limit of the cell. All testing is performed ina room controlled at 23° C.±3° C. and 50%±2% relative humidity.

Referring to FIG. 8, a bottom stationary fixture 800 comprising two bars3.175 mm in diameter by 60 mm in length, made of polished stainlesssteel are each mounted on their own fork 820. These 2 bars are mountedhorizontally, aligned front to back and parallel to each other, with topradii of the bars vertically aligned. Furthermore, the fixture 800allows for the two bars to be moved horizontally away from each other ona track 830 so that a gap can be set between the bars while maintainingtheir orientation. A top movable fixture 850 comprises a third bar also3.175 mm in diameter by 60 mm in length, made of polished stainlesssteel mounted on a fork 860. The bar of the top fixture 860 should beparallel to, and aligned front to back with the bars of the bottomfixture 800. Both fixtures 800 and 860 include an integral adapterappropriate to fit the respective position on the tensile tester frameand lock into position such that the bars are orthogonal to the motionof the crossbeam of the tensile tester.

Set the gap between the bars of the lower fixture 800 to 30 mm±0.5 mm(center of bar to center of bar) with the upper bar centered at themidpoint between the lower bars. Set the gage (bottom of top bar to topof lower bars) to 1.0 cm.

Sample Preparation:

Samples are conditioned at 23° C.±3° C. and 50%±2% relative humidity twohours prior to testing. The article is removed from its wrap and ifpresent, the release paper of the removed article to expose the pantyfastening adhesive (PFA). Apply talc powder to the PFA on the back sheetto mitigate tackiness. Cut a square specimen 50 mm in the longitudinaldirection of the article (MD) and 50 mm in the lateral direction (CD) ofthe article from the center of the article. Sample should offset fromany folds that are present in the article. The orientation of the sampleshould be maintained such that the MD direction and the CD direction,each of which is imputed from the article to the sample, is preservedmaintaining their orientation after they are cut. Measure the caliper ofeach specimen, using a digital caliper (e.g. Ono Sokki GS-503 orequivalent) fitted with a 25 mm diameter foot that applies a confiningpressure of 0.1 PSI. Read the caliper (mm) 5 sec after resting the footon the sample and record to the nearest 0.01 mm.

Program the tensile tester for a compression test, to move the crossheaddown at a rate of 0.5 mm/sec until the upper bar touches the top surfaceof the specimen, then continue for an additional 14 mm collecting force(N) and displacement (m) data at 25 Hz, and return the crosshead to itsoriginal gage. Load a specimen such that it spans the two lower bars andis centered under the upper bar with its sides parallel to the bars.Zero the crosshead and load cell. Start the run and collect data. Theorientation of the sample on the bottom fixture 800 should be recordedand associated with obtained data in the particular orientation. Wherethe sample is oriented such that the MD direction is perpendicular tothe long axis of the bars of the bottom fixture 800, the data beingobtained is with regard to the MD direction of the article. Similarly,where the sample is oriented such that the CD direction is perpendicularto the long axis of the bars of the bottom fixture 800, the data beingobtained is with regard to the CD direction of the article.

Construct a graph of force (N) verses displacement (mm). Read theMaximum Peak Force (N) from the graph and record to the nearest 0.1N.Calculate the Flexural Strength of the specimen as the Maximum PeakForce (N)/Sample Area (m²) and report to the nearest 0.1 kPa. Calculatethe Handleability as [0.5× Maximum Peak Force (N)× Displacement at Peak(mm)]/Specimen Caliper (mm) and record to the nearest 0.01N.

Measures are repeated in like fashion for 10 MD and 10 CD samples andreport the average separately for each of the ten values to the nearest0.1 N for Peak Force, 0.1 kPa for Flexural Strength, and 0.01N forHandleability.

Post Elongation Recovery

This method is used to determine the post elongation strain of barriercuffs as a function of temperature and time. The measurement is done at22° C. (72° F.) or at 32° C. (90° F.). The measurement at 22° C. (72°F.) is designed to simulate the recovery of the barrier cuffs at roomtemperature, while the measurement at 32° C. (90° F.) is designed tomeasure the recovery of the elastic members near skin temperature. Atwo-step analysis, Stretch and Recovery, is performed on the samples.The method employs a Dynamic Mechanical Analyzer. A TA Instruments DMA2980 (hereinafter “DMA 2980”), available from TA Instruments, Inc., ofNew Castle, Del.; equipped with a film clamp, Thermal Advantage/ThermalSolutions software for data acquisition, and Universal Analysis 2000software for data analysis was used herein. Many other types of DMAdevices exist, and the use of dynamic mechanical analysis is well knownto those skilled in the art of polymer and copolymer characterization.

Methods of operation, calibration and guidelines for using the DMA 2980are found in TA Instruments DMA 2980 Operator's Manual issued March2002, Thermal Advantage User's Reference Guide issued July 2000 andUniversal Analysis 2000 guide issued February 2003. To those skilled inthe use of the DMA 2980, the following operational run conditions shouldbe sufficient to replicate the stretch and recovery of the samples.

The DMA 2980 was configured to operate in the Controlled Force Mode withthe film clamp. The film clamp is mounted onto the DMA 2980 andcalibrated according to the User's Reference Guide. The barrier cuff tobe tested is cut into samples of substantially uniform dimension. Forthe DMA 2980, suitable sample dimensions are approximately 20 mm×6.4mm×1.0 mm (length×width×thickness). The sample thickness is dependent onthe materials and structure of the barrier cuff and on the confiningpressure used to measure the thickness. TA Instruments recommends thesample thickness, when securely mounted within the film clamps, to beless than or equal to about 2.0 mm. The lower film clamp of the DMA 2980is adjusted and locked in a position which provides approximately 10 mmbetween the clamping surfaces. The sample is mounted in the film clampsand the lower clamp is allowed to float to determine the gauge lengthbetween the film clamps. The sample ID and dimensions are recorded. Thefilm clamp is locked in position and the furnace is closed.

Stretch Method—

For the sample dimensions specified above, the DMA 2980 is configured asfollows: Preload force applied to sample in clamp (0.01N); auto zerodisplacement (on) at the start of the test; furnace (close), clampposition (lock), and temperature held at T_(i) (22° C. or 32° C.) at theend of the stretch method. Data acquisition rate is set at 0.5 Hz (1point per 2 seconds). The stretch method is loaded onto the DMA 2980.The method segments are (1) Initial Temperature T_(i) (22° C. or 32°C.), (2) Equilibrate at T_(i) (3) Data Storage ON, and (4) Ramp Force5.0 N/min to 18.0 N.

Upon initiation of the test, the temperature ramps to the specifiedT_(i) (22° C. or 32° C.) [method segment 1], and the temperature ismaintained at this T_(i) [method segment 2]. After a minimum of 15minutes at T_(i), the operator initiates the sample stretching andconcurrent data collection [method segments 3 and 4]. The sample isstretched with an applied ramp force of 0.8 N/min per millimeter ofinitial sample width (e.g., for the sample dimensions specified above,the applied ramp force is 5 N/minute) to approximately 30 mm in length.The gradual increase in force more closely simulates application of thearticle and prevents sample breakage. The sample is locked in place atthe stretched length of approximately 30 mm and maintained at T_(i). Theforce required to stretch the barrier cuff to a length of approximately30 mm and the percent strain of the laminate at this length are recordedmanually from the digital readout on the instrument. The percent strainis calculated by subtracting the gauge length from the stretched length,then dividing the result by the gauge length and multiplying by 100. Theinitial percent strain is described by the equation below:

Initial Percent Strain=% Strain_(i)=100*((Ls−L _(g))/L _(g))

where L_(g) is the length of the gathered stretch laminate in a relaxedstate and Ls is the length of the stretched laminate between the filmclamps at the end of the stretch step of the analysis (˜30 mm). %Strain_(i) is the percent strain of the stretch laminate at the start ofthe recovery method (i.e. after the stretch part of the method iscomplete). A sample stretched from a gauge length of 10 mm to a lengthof 30 mm results in a percent strain of 200%.

For purposes of this test, the maximum percent strain (e.g., 200%, 150%,or 100%) is to be chosen such that the strain does not result inirreversible deformation, delamination, or tearing of the barrier cuff.If the barrier cuff has an extensibility of less than 200% engineeringstrain (±5%), a new specimen of the sample is stretched from a gaugelength of 12 mm to an extended length of 30 mm which results in apercent strain of 150% engineering strain. If the barrier cuff has anextensibility of less than 150% engineering strain (±5%), a new specimenof the sample is stretched from a gauge length of 15 mm to an extendedlength of 30 mm which results in a percent strain of 100% engineeringstrain. Testing of barrier cuffs with maximum extensibility of <100% isalso within the scope of this method. For barrier cuffs tested at aninitial percent strain of 100% or less, the post elongation strain isreported as the percent strain rather than the percent of initial %strain at the different times of recovery (15 seconds, 30 seconds, 60seconds and 3 minutes).

For samples of different dimensions, the applied force to stretch thesample is adjusted to achieve an applied ramp force of 0.8 N/min permillimeter of initial sample width. For example, a force ramp of 2.5N/min is applied to a sample with an initial width of 3.2 mm. Forsamples of different lengths, the total displacement during theelongation is adjusted to achieve an initial percent strain of 200% (orless if the sample has limited extensibility, i.e. 150% or 100% strain).

Recovery Method—

The Recovery Method is loaded onto the instrument and initiatedapproximately 15 seconds after reaching the desired initial percentstrain (i.e. 200%, 150%, or 100%) in the Stretch Method. The foursegments of the recovery method are (1) Data Storage ON, (2) Force0.01N, (3) Ramp to T_(i), and (4) Isotherm for 3.0 minutes. Thefollowing DMA 2980 parameter setting is changed from the Stretch Method:auto zero displacement is changed to (OFF). The Recovery Method measuresthe length of the sample over a 3 minute time period at the specifiedtemperature (T_(i)=either 22° C. or 32° C.). The sample length, percentstrain, and test temperature are recorded as a function of recoverytime. The post elongation strain is reported as the percent of theinitial percent strain after different times of recovery (15 seconds, 30seconds, 60 seconds, and 3 minutes).

For samples of different dimensions, the force applied to the sampleduring recovery (segment 2 above) is adjusted to achieve an appliedforce of 0.0016 N per millimeter of initial sample width (0.01N for 6.4mm wide sample). For example, a force of 0.005 N is applied to a sample3.2 mm wide.

Two Cycle Hysteresis Test

This method is used to determine properties that may correlate with theforces experienced by the consumer during application of the productcontaining the slow recovery barrier cuffs and how the product fits andperforms once it is applied.

The two cycle hysteresis test method is performed at room temperature(21° C./70° F.) and also at body temperature (37° C./99° F.). Thebarrier cuff to be tested is cut into a sample of substantiallyrectilinear dimensions. Sample dimensions are selected to achieve therequired strain with forces appropriate for the instrument. Suitableinstruments for this test include tensile testers commercially availablefrom MTS Systems Corp., Eden Prairie, Minn. (e.g. Alliance RT/1 orSintech 1/S) or from Instron Engineering Corp., Canton, Mass. The samplethickness is dependent on the materials and structure of the barriercuff and on the confining pressure used to measure the thickness. Thethicknesses of samples are typically 0.5 mm to 5 mm thick measured with0.2 psi confining pressure. However, testing of barrier cuffs withdifferent thicknesses (e.g., <0.5 mm or >5 mm) is within the scope ofthis method.

The following procedure illustrates the measurement when using the abovesample dimensions and either an Alliance RT/1 or Sintech 1/S. Theinstrument is interfaced with a computer. TestWorks 4™ software controlsthe testing parameters, performs data acquisition and calculation, andprovides graphs and data reports.

The widths of the grips used for the test are greater than or equal tothe width of the sample. Typically 1″ (2.54 cm) wide grips are used. Thegrips are air actuated grips designed to concentrate the entire grippingforce along a single line perpendicular to the direction of testingstress having one flat surface and an opposing face from which protrudesa half round (radius=6 mm) to minimize slippage of the sample. In thecase of the measurement at 37° C., the upper grip is a lightweight gripwith serrated faces.

The load cell is selected so that the forces measured will be between10% and 90% of the capacity of the load cell or the load range used.Typically a 25 N load cell is used. The fixtures and grips areinstalled. The instrument is calibrated according to the manufacturer'sinstructions. The distance between the lines of gripping force (gaugelength) is 2.50″ (63.5 mm), which is measured with a steel ruler heldbeside the grips. The load reading on the instrument is zeroed toaccount for the mass of the fixture and grips. The specimen isequilibrated a minimum of 1 hour at 21° C. before testing. The specimenis mounted into the grips in a manner such that there is no slack andthe load measured is between 0.00 N and 0.02 N. The instrument islocated in a temperature-controlled room for measurements performed at21° C. A suitable environmental chamber is used to maintain the testingtemperature for measurements performed at 37° C.; the sample is mountedin the grips and equilibrated for 5 minutes at 37° C. before startingthe test.

The 2 cycle hysteresis test method involves the following steps:

-   (1) Strain the sample to the specified initial percent strain (i.e.,    Strain=150%) at a constant crosshead speed of 20″/min. (50.8 cm/min)    with no hold.-   (2) Reduce the strain to 0% strain (i.e., return grips to the    original gauge length of 2.50″) at a constant crosshead speed of    3″/min. (7.62 cm/min) with no hold.-   (3) Strain the sample to Strain_(i), at a constant crosshead speed    of 20″/min. (50.8 cm/min) with no hold.-   (4) Reduce strain to 60% strain at a constant crosshead speed of    3″/min. (7.62 cm/min)-   (5) Hold the sample at 60% strain for 5 minutes.-   (6) Go to 0% strain at a constant crosshead speed 3″/min. (7.62    cm/min)

The reported unload force is the measured unload force of the barriercuff (BC) at 60% strain after the 5 minute hold in step 5, normalized toNewton per 1 meter width of BC* basis weight of elastomer+adhesive (E+A)in the BC, N/(m·gsm)=N/(g/m), as shown in the equation below. The basisweight of the elastic and adhesive in the BC is calculated by dividingthe grams of elastomer+adhesive in the BC by the area of the BC fullyextended. The area of the fully extended barrier cuff (A_(FEBC)) isdefined as the area of the substrate of the barrier cuff in the absenceof elastic and adhesive. The normalized unload force in

${N/\left( {m \cdot {gsm}} \right)} = {{N/\left( {g/m} \right)} = {\frac{{measured}\mspace{14mu} {unload}\mspace{14mu} {force}\mspace{14mu} (N)}{\left\lbrack {{width}\mspace{14mu} {of}\mspace{14mu} {BC}\mspace{20mu} {in}\mspace{20mu} {meters}*\left( {{\left( {{{grams}\mspace{14mu} {of}\mspace{14mu} E} + A} \right) \div A_{FEBC}}\mspace{14mu} {in}\mspace{14mu} m^{2}} \right)} \right\rbrack}.}}$

For different sample dimensions, the crosshead speed is adjusted tomaintain the appropriate strain rate for each portion of the test. Forexample, a crosshead speed of 10″/min (25.4 cm/min) would be used inSteps 1 and 3 for a sample gauge length of 1.25″ (31.7 mm).

For each of the Post Elongation Recovery Test and the Two CycleHysteresis Test, barrier cuffs from feminine pads should be removed fromtheir respective articles. The removal should ensure that structurally,the barrier cuff, i.e. elastic and cover, are in-tact as much aspossible. As such, removal methods should preferably not structurallymodify the behavior of the elastic members and/or the cover. So,solvents utilized to dissolve glues for discrete cuffs should becarefully selected. For those barrier cuffs which are integral to thechassis, these barrier cuffs should be cut out of the chassis ensuringthat the outboard most portions of adhesive attaching the elastic to thetopsheet and/or backsheet is including in the portion being cut from thechassis. Samples are then prepared as noted above with regard to thesemethods.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited herein, including any cross referenced or relatedpatent, patent publication, or patent application, is herebyincorporated by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests, or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular forms of the present disclosure have been illustratedand described, those of skill in the art will recognize that variousother changes and modifications can be made without departing from thespirit and scope of the invention. It is therefore intended to cover inthe appended claims all such changes and modifications that are withinthe scope of the present disclosure.

What is claimed is:
 1. A disposable absorbent article having alongitudinal axis and a lateral axis perpendicular to the longitudinalaxis, the disposable absorbent article further comprising: a chassishaving first and second longitudinal side edges extending generallyparallel to the longitudinal axis, a pair of end edges joining the firstand second longitudinal side edges on opposite ends of the chassis, thechassis further comprising a topsheet; a backsheet; and an absorbentcore disposed between the topsheet and the backsheet; a fasteningadhesive disposed on a garment-facing surface of the chassis; a firstcuff extending along the first longitudinal side edge; and a second cuffextending along the second longitudinal edge, wherein the article has aflexibility factor of less than 240 and an average pad curl of less than3.0 mm.
 2. The disposable absorbent article of claim 1, wherein theaverage pad curl is less than 2 mm.
 3. The disposable absorbent articleof claim 1, wherein the average cross direction peak load is less than160 grams force.
 4. The disposable absorbent article of claim 1, whereinthe first cuff and the second cuff comprise a portion of the topsheetand the backsheet.
 5. The disposable absorbent article of claim 1,wherein the first cuff comprises a first cover and the second cuffcomprises a second cover, wherein first cover and second cover arediscrete from the chassis of the absorbent article.
 6. The disposableabsorbent article of claim 5, wherein the first cover and the secondcover are attached to the topsheet.
 7. The disposable absorbent articleof claim 1, wherein the flexibility factor is less than
 230. 8. Thedisposable absorbent article of claim 1, wherein the flexibility factoris less than
 220. 9. The disposable absorbent article of claim 1,wherein the flexibility factor is less than
 212. 10. The disposableabsorbent article of claim 1, wherein the flexibility factor is between50 and
 220. 11. The disposable absorbent article of claim 1, wherein theaverage pad curl is less than 2.0 mm.
 12. The disposable absorbentarticle of claim 1, wherein the average pad curl is between 0.5 mm and2.5 mm.
 13. The disposable absorbent article of claim 1, wherein theaverage pad curl is between 1.0 mm and 2.0 mm.
 14. A disposableabsorbent article having a longitudinal axis and a lateral axisperpendicular to the longitudinal axis, the disposable absorbent articlefurther comprising: a chassis having first and second longitudinal sideedges extending generally parallel to the longitudinal axis, a pair ofend edges joining the first and second longitudinal side edges onopposite ends of the chassis, the chassis further comprising a topsheet;a backsheet; and an absorbent core disposed between the topsheet and thebacksheet; a fastening adhesive disposed on a garment-facing surface ofthe chassis; a first cuff extending along the first longitudinal sideedge; and a second cuff extending along the second longitudinal edge,wherein the article has a flexibility factor of less than 190 and anaverage pad curl of less than 7.5 mm.
 15. The disposable absorbentarticle of claim 14, wherein the average pad curl is less than 7.0 mm.16. The disposable absorbent article of claim 14, wherein the averagepad curl is less than 4.0 mm.
 17. The disposable absorbent article ofclaim 14, wherein the average pad curl is less than 3.0 mm.
 18. Thedisposable absorbent article of claim 14, wherein the average pad curlis between 0.5 mm and 4.0 mm.
 19. The disposable absorbent article ofclaim 14, wherein the average pad curl is between 1.0 mm and 3.0 mm. 20.The disposable absorbent article of claim 14, wherein the flexibilityfactor is less than
 180. 21. The disposable absorbent article of claim14, wherein the flexibility factor is between 50 and
 190. 22. Thedisposable absorbent article of claim 14, wherein the first cuff and thesecond cuff comprise a portion of the topsheet and the backsheet. 23.The disposable absorbent article of claim 14, wherein the first cuffcomprises a first cover and the second cuff comprises a second cover,wherein first cover and second cover are discrete from the chassis ofthe absorbent article.
 24. The disposable absorbent article of claim 23,wherein the first cover and the second cover are attached to thetopsheet.
 25. A disposable absorbent article having a longitudinal axisand a lateral axis perpendicular to the longitudinal axis, thedisposable absorbent article further comprising: a chassis having firstand second longitudinal side edges extending generally parallel to thelongitudinal axis, a pair of end edges joining the first and secondlongitudinal side edges on opposite ends of the chassis, the chassisfurther comprising a topsheet; a backsheet; and an absorbent coredisposed between the topsheet and the backsheet; a fastening adhesivedisposed on a garment-facing surface of the chassis; a first cuffextending along the first longitudinal side edge; and a second cuffextending along the second longitudinal edge, wherein the article has anaverage pad curl that satisfies the following equation:APC≦(−0.0338 FF+8.7879).
 26. The disposable absorbent article of claim25, wherein the first cuff and the second cuff comprise a portion of thetopsheet and the backsheet.
 27. The disposable absorbent article ofclaim 25, wherein the first cuff comprises a first cover and the secondcuff comprises a second cover, wherein first cover and second cover arediscrete from the chassis of the absorbent article.
 28. The disposableabsorbent article of claim 27, wherein the first cover and the secondcover are attached to the topsheet.
 29. The disposable absorbent articleof claim 25, wherein the average pad curl is less than 9.0 mm.
 30. Thedisposable absorbent article of claim 25, wherein the average pad curlis less than 7.0 mm.
 31. The disposable absorbent article of claim 25,wherein the average pad curl is between 0.5 mm and 3.0 mm.
 32. Thedisposable absorbent article of claim 25, wherein the flexibility factoris less than
 260. 33. The disposable absorbent article of claim 25,wherein the flexibility factor is less than 240.